EP2939931A1 - Système de fabrication flexible pour des structures d'aéronefs - Google Patents

Système de fabrication flexible pour des structures d'aéronefs Download PDF

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Publication number
EP2939931A1
EP2939931A1 EP14196553.3A EP14196553A EP2939931A1 EP 2939931 A1 EP2939931 A1 EP 2939931A1 EP 14196553 A EP14196553 A EP 14196553A EP 2939931 A1 EP2939931 A1 EP 2939931A1
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EP
European Patent Office
Prior art keywords
drivable
location
autonomous tool
drivable support
supports
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP14196553.3A
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German (de)
English (en)
Other versions
EP2939931B1 (fr
Inventor
Dan Dresskell DAY
Clayton Lynn Munk
Steven John Schmitt
Eric M. Reid
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Boeing Co
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Boeing Co
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Filing date
Publication date
Application filed by Boeing Co filed Critical Boeing Co
Publication of EP2939931A1 publication Critical patent/EP2939931A1/fr
Application granted granted Critical
Publication of EP2939931B1 publication Critical patent/EP2939931B1/fr
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P21/00—Machines for assembling a multiplicity of different parts to compose units, with or without preceding or subsequent working of such parts, e.g. with programme control
    • B23P21/004—Machines for assembling a multiplicity of different parts to compose units, with or without preceding or subsequent working of such parts, e.g. with programme control the units passing two or more work-stations whilst being composed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B41/00—Boring or drilling machines or devices specially adapted for particular work; Accessories specially adapted therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64F—GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
    • B64F5/00—Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for
    • B64F5/10—Manufacturing or assembling aircraft, e.g. jigs therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2215/00—Details of workpieces
    • B23B2215/04—Aircraft components
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/50—Convertible metal working machine
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T408/00—Cutting by use of rotating axially moving tool
    • Y10T408/03—Processes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T408/00—Cutting by use of rotating axially moving tool
    • Y10T408/52—Cutting by use of rotating axially moving tool with work advancing or guiding means

Definitions

  • the present disclosure relates generally to aircraft and, in particular, to manufacturing aircraft structures. Still more particularly, the present disclosure relates to a method and apparatus for performing operations to manufacture aircraft structures using an automated drivable assembly system.
  • Manufacturing aircraft structures may be a complex and time-consuming process. Thousands of parts may be designed and assembled to complete an aircraft structure. Progressive assembly of these parts may be completed by moving the aircraft structure to different locations in the manufacturing facility. Various operations are performed on the aircraft structure in each of the locations.
  • a "fixed monument fixture” is a structure that is immovably connected to the facility floor, wall, or other portion of the manufacturing facility.
  • a fixed monument fixture that is bolted to the facility floor may be used to hold an aircraft structure in a desired position while it is being assembled.
  • Human operators and their tools maneuver about these fixed monument fixtures to perform operations on the aircraft structure For instance, human operators may bring various parts to the fixed monument fixture, position those parts relative to the aircraft structure held by the fixed monument fixture, and perform operations such as drilling, fastening, coating, and inspecting, among others. Countless labor hours are needed for human operators to assemble and inspect the aircraft structure.
  • the aircraft structure may be removed from the fixed monument fixture and moved to a new location within the manufacturing facility. In the new location, the structure may again be secured to a fixed monument fixture, recalibrated, and assembled. The movement and repositioning of the aircraft structure may cause undesired delays in the manufacturing process, which increase the production time for the aircraft structure.
  • the process of using fixed monument fixtures may take up more room than desired in the manufacturing facility, allow limited access to the aircraft structure for human operators, or both.
  • the need for human operators to transport parts to fixed monument fixtures and maneuver within and around these fixed monument fixtures also may increase the time, complexity, and cost of assembling the aircraft more than desired.
  • fixed monument fixtures may be difficult to modify or move since fixed monument fixtures are heavy, secured to the floor, or both. Therefore, fixed monument fixtures may be inflexible and may be useful for only one assembly build configuration. Accordingly, there is a need for a method and apparatus that provides a more efficient, flexible, higher production rate process for assembling aircraft without the use of fixed monument fixtures attached to the manufacturing facility floor.
  • a flexible manufacturing system for an aircraft structure may comprise a drivable support.
  • the drivable support may be driven from a first location and brought together with at least one other drivable support to form a drivable support system at a second location on a floor of a manufacturing environment.
  • the drivable support system may be configured to hold a structure in a desired position.
  • a method for manufacturing an aircraft structure may be provided.
  • a drivable support may be driven from a first location to a second location to bring the drivable support together with at least one other drivable support to form a drivable support system.
  • a structure may be held in a desired position using the drivable support system.
  • a flexible manufacturing system may comprise a drivable support, a plurality of autonomous tool systems, a metrology system, and a controller in communication with the metrology system, the drivable support system, and the plurality of autonomous tool systems.
  • the drivable support may be configured to be driven from a first location and brought together with at least one other drivable support to form a drivable support system at a second location on a floor of a manufacturing environment.
  • the drivable support system may be configured to hold the structure in a desired position.
  • the drivable support system and the structure may be configured to drive to a third location while operations are being performed on the structure.
  • the plurality of autonomous tool systems may be configured to perform the operations on the structure.
  • the plurality of autonomous tool systems may be further configured to drive across the floor of the manufacturing environment.
  • the metrology system may be configured to determine a current position for at least one of the drivable support system, the plurality of autonomous tool systems, or the structure.
  • the controller may be configured to control operation of at least one of the drivable support system or the plurality of autonomous tool systems.
  • a system for manufacturing an aircraft structure may comprise a group of crawler robots and a mobile platform.
  • the group of crawler robots may be positioned on a structure.
  • the group of crawler robots may be configured to move along a surface of the structure to install fasteners in the structure.
  • the mobile platform may be configured to drive across a floor of a manufacturing environment.
  • the mobile platform may be further configured to place the group of crawler robots on the surface of the structure.
  • a method for manufacturing an aircraft structure may be provided.
  • a drivable platform may be driven across a floor of a manufacturing environment to place a group of crawler robots on a structure.
  • the group of crawler robots may be positioned relative to a surface of the structure to install fasteners in the structure.
  • a system for manufacturing an aircraft structure may comprise a hexapod and a movement system associated with the hexapod.
  • the hexapod may be positioned relative to a surface of a structure.
  • the hexapod may be configured to move relative to the surface of the structure to install a fastener in the structure.
  • the movement system may be configured to drive the hexapod across a floor of a manufacturing environment to position the hexapod relative to the structure.
  • a method for manufacturing an aircraft structure may be provided.
  • a hexapod may be driven across a floor of a manufacturing environment to position the hexapod relative to a structure using a movement system associated with the hexapod.
  • the hexapod may be positioned relative to a surface of the structure to install a fastener in the structure.
  • a flexible manufacturing system for a structure may comprise a mobile support system, a plurality of autonomous tool systems, a metrology system, and a controller in communication with the metrology system and the plurality of autonomous tool systems.
  • the mobile support system may be configured to hold the structure in a desired position.
  • the mobile support system may be further configured to carry the structure between a plurality of work cells during a performance of operations for manufacturing the structure.
  • the plurality of autonomous tool systems may be configured to perform the operations on the structure.
  • the plurality of autonomous tool systems may be further configured to move with the mobile support system.
  • the metrology system may be configured to generate metrology data for at least one of the mobile support system, the plurality of autonomous tool systems, or the structure.
  • the controller may be configured to control operation of the plurality of autonomous tool systems using the metrology data.
  • a flexible manufacturing system for a structure may comprise a translatable support system, a plurality of autonomous tool systems, a metrology system, and a controller in communication with the metrology system and the plurality of autonomous tool systems.
  • the translatable support system may be configured to hold the structure in a desired position.
  • the translatable support system may be further configured to move with the structure from a first location to a second location during a performance of operations for manufacturing the structure.
  • the plurality of autonomous tool systems may be configured to perform the operations on the structure.
  • the plurality of autonomous tool systems may be further configured to move with the translatable support system.
  • the metrology system may be configured to generate metrology data for at least one of the translatable support system, the plurality of autonomous tool systems, or the structure.
  • the controller may be configured to control operation of the plurality of autonomous tool systems using the metrology data.
  • a method for positioning a tool on a surface may be provided.
  • the tool may be moved relative to the surface to roughly position the tool within a selected region on the surface using a first movement system.
  • the tool may be further moved relative to the surface with at least one degree of freedom to precisely position the tool at a selected position within the selected region on the surface using a second movement system.
  • a method for positioning a tool on a surface may be provided.
  • the tool may be moved relative to the surface to roughly position the tool within a selected region on the surface using a first movement system.
  • the tool may be further moved relative to the surface with at least one degree of freedom to precisely position the tool at a selected position within the selected region on the surface using a second movement system.
  • An element associated with the tool may be aligned for performing an operation at the selected position relative to the selected position using a third movement system.
  • a flexible manufacturing system for an aircraft structure may comprise a first group of drivable supports, a second group of drivable supports, a first elongate platform and a second elongate platform.
  • the first group of drivable supports may be driven from a first location and brought together with the second group of drivable supports at a second location on a floor of a manufacturing environment.
  • the first elongate platform may be connected to the first group of drivable supports.
  • the first group of drivable supports may drive the first elongate platform to the second location.
  • the second elongate platform may be connected to the second group of drivable supports.
  • the second group of drivable supports may drive the second elongate platform to the second location.
  • the first elongate platform and the second elongate platform may hold a structure in a desired location and may carry the structure through the manufacturing environment.
  • a method for manufacturing an aircraft structure may be presented.
  • a first group of drivable supports, connected to a first elongate platform may be driven from a first location to a second location on a floor of a manufacturing environment.
  • a second group of drivable supports, connected to a second elongate platform may be driven to position the second elongate platform relative to the first elongate platform.
  • a structure used to form the aircraft structure may be connected to the first elongate platform and the second elongate platform. The structure may be held in a desired position using the first elongate platform and the second elongate platform.
  • the illustrative embodiments recognize and take into account one or more different considerations. For example, without limitation, the illustrative embodiments recognize and take into account that it may be desirable to assemble an aircraft structure without the use of fixed monument fixtures at different locations within the manufacturing facility. These fixed monument fixtures may be large, bulky, structures that take up significant amounts of space in the manufacturing facility. As a result, the number of work cells available in the manufacturing facility may be limited, which reduces the number of aircraft structures that may be assembled at the same time.
  • the illustrative embodiments recognize and take into account that when maintenance or rework needs to be performed on the fixed monument fixtures, production of aircraft structures may be slowed until the fixed monument fixture is repaired. Fixed monument fixtures are not easily replaceable without significantly reducing the production rate of aircraft structures within the manufacturing facility.
  • the illustrative embodiments also recognize and take into account that it may be desirable to reconfigure devices in an assembly system based on the layout of the manufacturing facility being used, the type of aircraft structure being built, or a combination thereof. For instance, it may be desirable to a manufacturer to bring a number of devices to an empty manufacturing environment, where no fixed monument fixtures or other structures are present. The manufacturer may then arrange or assemble the devices as needed to promote efficient manufacturing of the aircraft structure. After initially arranging such devices, the illustrative embodiments recognize and take into account that it may be desirable to rearrange the devices, change the configuration of the devices, modify the length of the assembly line, perform more operations at a single location, or make some other change or adjustment. In other words, it may be desirable for the devices to be arranged and rearranged to form many different non-fixed fixtures.
  • the illustrative embodiments further recognize and take into account that it may be desirable to increase the speed at which an aircraft structure is assembled. For example, without limitation, it may be desirable to automate various operations using robotic devices. As another example, it may be desirable to move the aircraft structure between locations in the manufacturing facility without disconnecting the aircraft structure from the fixture holding the aircraft structure. It also may be desirable to move the aircraft structure to another location without having to place the aircraft structure back onto another set of fixed monument fixtures before performing additional operations. All of these actions require reconfiguration of the aircraft structure which may increase the time, complexity, and cost of manufacturing the aircraft structure.
  • the illustrative embodiments may provide a method and apparatus for performing operations on an aircraft structure.
  • This aircraft structure may take the form of a wing, a fuselage, a stabilizer, a flap, a door, a slat, an aileron, a spoiler, or other component for an aircraft or some other non-aircraft structure.
  • a flexible manufacturing system may include a drivable support driven from a first location and brought together with at least one other drivable support to form a drivable support system, or non-fixed fixture, at a second location on a floor of a manufacturing environment.
  • the drivable support system may be configured to hold a structure in a desired position and drive the drivable support system carrying the assembly to a third location while operations are being performed on the assembly.
  • manufacturing environment 100 is an environment in which flexible manufacturing system 102 may be used to manufacture product 104.
  • manufacturing environment 100 may be empty before flexible manufacturing system 102 is initially arranged within manufacturing environment 100.
  • manufacturing environment 100 may be an empty manufacturing facility, building, unit, or other suitable location used to manufacture product 104.
  • Flexible manufacturing system 102 may be moved into manufacturing environment 100, arranged, and reconfigured as needed to promote efficient manufacturing of product 104.
  • Flexible manufacturing system 102 may be a manufacturing system having the flexibility to change to produce new product types, the ability to change the order of operations executed on a part for product 104, the ability to use multiple devices to perform the same operation on a part, the ability to handle large-scale changes in volume, capacity, or capability, or some combination thereof.
  • flexible manufacturing system 102 may be a manufacturing system that is at least partially automated.
  • flexible manufacturing system 102 is a substantially fully automated system for manufacturing product 104.
  • Flexible manufacturing system 102 may be movable and reconfigurable in this illustrative example.
  • one or more components in flexible manufacturing system 102 may be movable to various locations 103 in manufacturing environment 100. None of the components in flexible manufacturing system 102 are fixed in a specified location.
  • a device that is "movable” may mean that the item can move or be moved.
  • a movable device may take the form of a mobile device.
  • a device that is "mobile” may be able to move from one location in three-dimensional space to another location in three-dimensional space.
  • an entirety of the device which may include all of the components that make up the device, may be capable of moving or being moved from one location in three-dimensional space to another location in three-dimensional space. In this manner, the device is not fixed to a particular location.
  • flexible manufacturing system 102 When flexible manufacturing system 102 includes mobile devices, flexible manufacturing system may be referred to as a mobile assembly system. Flexible manufacturing system 102 does not include a fixed monument fixture in this illustrative example. In some cases, a mobile device may take the form of a drivable device.
  • a device that is "drivable” may be able to move from one location in three-dimensional space to another location in three-dimensional space as described above. Movement of a drivable device may be controlled using, for example, without limitation, a controller for the device, a system controller for flexible manufacturing system 102, or some other type of controller.
  • movement of a drivable device may be controlled at least one of electronically, mechanically, electromechanically, or manually.
  • a drivable device may be capable of moving or being moved in its entirety in a number of different ways.
  • movement of a drivable device may be both electronically and manually controlled.
  • the device may be drivable across floor 107 of manufacturing environment 100 to assemble product 104.
  • product 104 is a physical object that is comprised of any number of parts, components, sub-assemblies, assemblies, or systems. These items may be assembled to form product 104. In some cases, product 104 may be partially assembled in manufacturing environment 100 and then moved to another location for additional assembly. Product 104 may be referred to as a structure, an aircraft structure, a part, or an aircraft part in some instances.
  • product 104 may take the form of wing 108 for aircraft 109.
  • product 104 may take the form of an aircraft structure selected from one of a fuselage, a vertical stabilizer, a control surface, a horizontal stabilizer and other suitable structures.
  • product 104 may be an automobile, an aircraft, a ship, a satellite, an engine, a building, or other types of structures in some cases.
  • Structure 110 may correspond to product 104 during manufacturing of product 104. Specifically, structure 110 may be product 104 during various stages of manufacturing. In this manner, structure 110 may be one or more components used to form product 104, a partially completed product 104, or a fully completed product 104. In some illustrative examples, structure 110 may be referred to as an assembly for product 104.
  • structure 110 When structure 110 corresponds to wing 108, structure 110 may be referred to as wing assembly 105. In this depicted example, components may be added to structure 110 as structure 110 moves about manufacturing environment 100.
  • manufacturing environment 100 may include locations 103.
  • manufacturing environment 100 may include first location 113, second location 115, third location 117, and fourth location 119.
  • locations 103 may be different physical positions within manufacturing environment 100.
  • Manufacturing environment 100 may include plurality of work cells 112.
  • Plurality of work cells 112 are areas in manufacturing environment 100 where flexible manufacturing system 102 works on structure 110.
  • a location in locations 103 may correspond to a work cell in work cells 112 in some cases.
  • one or more of locations 103 may be in one of plurality of work cells 112.
  • Various tasks 111 may be performed in each work cell in plurality of work cells 112.
  • spars and ribs may be connected to each other to form a framework for wing 108.
  • skin panels may be attached to the framework.
  • a sealant, paint, or other materials may be applied to wing 108.
  • each work cell in plurality of work cells 112 may have dimensions 114.
  • Dimensions 114 may represent measurements of the size of each of the different work cells in plurality of work cells 112.
  • dimensions 114 may include a length, a width, a height, and other suitable dimensions for each work cell in plurality of work cells 112.
  • Dimensions 114 for each work cell in plurality of work cells 112 may be the same or different in this illustrative example. In some cases, dimensions 114 may change as structure 110 moves through plurality of work cells 112. In other cases, dimensions 114 may change based on at least one of a size or a layout of manufacturing environment 100.
  • the phrase "at least one of,” when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed.
  • the item may be a particular object, thing, or category.
  • "at least one of” means any combination of items or number of items may be used from the list, but not all of the items in the list may be required.
  • “at least one of item A, item B, and item C” may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C.
  • “at least one of item A, item B, and item C” may mean, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.
  • flexible manufacturing system 102 may comprise a number of different components.
  • a "number of" items may be one or more items.
  • a number of components may be one more components.
  • flexible manufacturing system 102 may include support system 101, plurality of autonomous tool systems 118, drive control system 121, navigator 124, transformer 126, and loading system 127. These systems may be referred to collectively as "components" in flexible manufacturing system 102.
  • At least one of the components in flexible manufacturing system 102 may be reconfigurable.
  • substantially all of the components in flexible manufacturing system 102 are reconfigurable depending on the particular implementation of flexible manufacturing system 102.
  • reconfigurable may refer to the ability of components within a system to be rearranged. This rearrangement may be in terms of a change in position of one component relative to another component. The position may be the location of the component using three-dimensional coordinates, the orientation of the component, or both.
  • the position of components within flexible manufacturing system 102 may be "dynamically reconfigured.” In other words, components within support system 101 may be rearranged in real-time as structure 110 is moved through manufacturing environment 100.
  • each component within support system 101 also may be independently reconfigurable. In other words, devices within each component may be rearranged, recalibrated, or otherwise changed during manufacturing of wing 108.
  • one or more of those devices may be reconfigured within the component without rearranging the position of the component relative to other components in flexible manufacturing system 102.
  • flexible manufacturing system 102 as a whole, as well as each component within flexible manufacturing system 102, may be dynamically reconfigured as needed.
  • reconfiguration 128 of those components has occurred.
  • reconfiguration 128 of components within flexible manufacturing system 102 may occur during manufacturing of product 104.
  • reconfiguration 128 of at least one of the components within flexible manufacturing system 102 may be performed based on changes in at least one of dimensions 114 in different work cells in plurality of work cells 112, status 129 of operations 130 for structure 110, or a status of any one of the components in flexible manufacturing system 102.
  • an autonomous tool system in plurality of autonomous tool systems 118 goes offline, another autonomous tool system in plurality of autonomous tool systems 118 may take over for the offline device. This action results in reconfiguration 128 of plurality of autonomous tool systems 118.
  • more of operations 130 may be performed in a single work cell.
  • reconfiguration 128 may include changing the order of operations 130.
  • each of the components within flexible manufacturing system 102 can move relative to other components in flexible manufacturing system 102, these components are moved to a desired position within manufacturing environment 100.
  • reconfiguration 128 may occur based on manufacturing parameters 132 for wing 108.
  • Manufacturing parameters 132 may include size of product 104 being manufactured, the type of plurality of autonomous tool systems 118 needed, a production rate, the materials used, safety considerations, airline regulations, other suitable parameters, or a combination thereof.
  • support system 101 may be used to support and hold structure 110 as structure 110 moves through manufacturing environment 100. In this manner, support system 101 carries structure 110 through manufacturing environment 100.
  • Support system 101 may include a number of components that drive across floor 107 in manufacturing environment 100.
  • support system 101 includes drivable components
  • support system 101 takes the form of drivable support system 116.
  • Drivable support system 116 may take the form of a rapid autonomous barge intelligent tool (RABIT) in some cases.
  • Drivable support system 116 may be referred to as a translatable support system or a mobile support system.
  • Drivable support system 116 may be configured to hold structure 110 in desired position 133 as it drives across floor 107.
  • drivable support system 116 may carry structure 110 between plurality of work cells 112 during performance of operations 130.
  • drivable support system 116 may comprise support structures 152 and bridge system 136. Drivable support system 116 also may be physically associated with rail system 138.
  • a first component such as drivable support system 116
  • a second component such as rail system 138
  • the first component also may be connected to the second component using a third component. Further, the first component may be considered to be associated with the second component by being formed as part of, as an extension of the second component, or a combination thereof.
  • support structures 152 each may be individually drivable. When support structures 152 are drivable, support structures 152 take the form of drivable supports 135.
  • Drivable support 137 is one of drivable supports 135 in this illustrative example. Drivable support 137 may be a device configured to be driven from first location 113 and brought together with at least one other drivable support in drivable supports 135 to form drivable support system 116 at second location 115 on floor 107 of manufacturing environment 100.
  • Drivable support system 116 may take the form of non-fixed fixture 169. In this manner, drivable support system 116 may function as a monument that is drivable, movable, translatable, or otherwise configured to be moved in its entirety between locations 103 in manufacturing environment 100. Once drivable support system 116 is formed, drivable support system 116 may be configured to carry structure 110 to third location 117 while operations 130 are being performed on structure 110. As an example, third location 117 may be a location in one of plurality of work cells 112. Drivable support system 116 also may carry structure 110 between a number of additional locations in manufacturing environment 100.
  • Each one of drivable supports 135 may be configured to hold one of parts 191 for structure 110 and drive across floor 107 of manufacturing environment 100 to position each respective part relative to one another under the command of controller 122 in drive control system 121.
  • drivable support 137 may carry a spar across floor 107 to position the spar relative to structure 110.
  • drivable support 137 may bring a group of ribs to structure 110.
  • Each of drivable supports 135 may be connected to structure 110 at different connection points 167 on structure 110 in this illustrative example.
  • Connection points 167 are physical locations on structure 110 to which drivable supports 135 connect.
  • each of drivable supports 135 may be a module that can be moved away from drivable support system 116 and replaced with another. In this manner, drivable support system 116 may be reconfigured for a different sized wing. As another example, a new drivable support may be used to replace one of drivable supports 135 that may malfunction or need maintenance, for some other reason, or a combination thereof.
  • Drivable supports 135 may be mechanical stanchions, upright supports, automated guided vehicles, pillars, or may take other forms in this illustrative example. Each of drivable supports 135 may be equipped with various mechanical and electrical components such as, for example, without limitation, a controller, an actuator, a clamping device, a pneumatic tool, a hydraulic tool, and other suitable devices configured to hold structure 110 in desired position 133.
  • each of drivable supports 135 may be associated with its own movement system. When drivable supports 135 are brought together to form drivable support system 116, the individual movement systems corresponding to drivable supports 135 may move collectively between locations 103.
  • a collective movement system may be configured to move drivable support system 116 in its entirety.
  • a tug or other type of movement system may be connected to one or more of drivable supports 135 to move or propel drivable support system 116 from one location to another location in manufacturing environment 100.
  • desired position 133 may be a configuration for structure 110 in three-dimensional space.
  • desired position 133 may include a location, an orientation, a height above floor 107, or some other suitable configuration in manufacturing environment 100. Desired position 133 may be selected based on the size of structure 110, the type of operations 130 being performed on structure 110, and other suitable parameters.
  • Drivable supports 135 may be associated with connection devices 195.
  • Connection devices 195 may be referred to as fixturing devices, fixturing points, connection points, or connection tools in some illustrative examples.
  • Connection devices 195 each may connect to a different one of connection points 167 on structure 110.
  • Connection devices 195 may be configured to connect to structure 110 at connection points 167 to hold at least a portion of structure 110 above floor 107.
  • Connection devices 195 may move vertically, tilt, or otherwise position the different parts 191 on structure 110.
  • Controller 122 may be configured to control each of connection devices 195 individually, to change its height, angle, length, or other parameters. Controller 122 also may be configured to control the collective of connection devices 195 corresponding to drivable supports 135 forming drivable support system 116.
  • controller 122 may be configured to extend or retract each of connection devices 195. In this manner, precise positioning of parts 191 of structure 110 may be completed to achieve desired position 133 for structure 110.
  • connection devices 195 may be configured to connect to structure 110 at control points 193.
  • Control points 193 are connection points 167 with additional functions.
  • Control point 171 may be one of control points 193.
  • Control point 171 may be a location on structure 110 that may be controllable such that control point 171 may be brought into alignment with a reference coordinate system for structure 110 or for product 104 being manufactured.
  • the reference coordinate system may be a reference coordinate system based on product 104 or the object or platform for which product 104 is being manufactured.
  • the reference coordinate system may be airplane coordinate system 183.
  • control point 171 may be at a known location on structure 110 with respect to airplane coordinate system 183.
  • Control point 171 may be used to transition between airplane coordinate system 183 and global coordinate system 181 for manufacturing environment 100.
  • Global coordinate system 181 may be identified using metrology system 120.
  • Global coordinate system 181 may be a shop or manufacturing coordinate system.
  • control point 171 in global coordinate system 181 may correspond with the location of control point 171 in airplane coordinate system 183.
  • locations within airplane coordinate system 183 at which particular operations are to be performed may be transformed into locations within global coordinate system 181.
  • locations within global coordinate system 181 at which particular operations are being performed may be transformed into locations within airplane coordinate system 183. These transformations may occur using transformer 126.
  • control point 171 may be used to transition between global coordinate system 181 for manufacturing environment 100 and a wing coordinate system for wing 108 or airplane coordinate system 183 for aircraft 109. In this manner, control point 171 may be used to locate structure 110 with respect to airplane coordinate system 183.
  • connection devices 195 corresponding to drivable supports 135 may be attached to the parts used to assemble a product, such as wing 108, at connection points 167.
  • This collective of connection devices 195 may hold parts 191 at connection points 167 to restrain assembly dimensional shape within tolerances.
  • the collective of connection devices 195 also may hold the parts in the desired position for assembly of wing 108.
  • Connection points 167 may be attachment points on the structure. For instance, connection points 167 may be leading or trailing edge attachment points or control surface hinge points for structures such as slats, spoilers, rudders, flaps, control surfaces, or other points where something can be attached to the structure during the build process.
  • drivable supports 135 may substantially prevent structure 110 from moving in an undesired manner.
  • Structure 110 may move in an undesired manner when structure 110 moves outside of selected tolerances.
  • structure 110 may move in an undesired manner when structure 110 tilts, sways, rotates, vibrates, or moves in some other manner outside of desired position 133.
  • drivable supports 135 may be connected to one another by platform structure 134.
  • platform structure 134 may be an object positioned under structure 110.
  • Platform structure 134 may comprise a number of platforms that connect drivable supports 135 to one another. In this manner, platform structure 134 may temporarily connect drivable supports 135.
  • Platform structure 134 and drivable supports 135 may then collectively carry structure 110 throughout plurality of work cells 112 from location to location.
  • platform structure 134 drives across floor 107, platform structure 134 may be referred to as a drivable platform structure.
  • bridge system 136 may be a structure connected to drivable supports 135.
  • drivable supports 135 may hold bridge system 136.
  • bridge system 136 may connect two or more drivable supports 135.
  • bridge system 136 may be connected to drivable supports 135 in some other manner.
  • bridge system 136 may be configured to provide access to structure 110 by human operator 142.
  • bridge system 136 may allow access for human operator 142 to a portion of structure 110 that would not otherwise be accessed from floor 107 of manufacturing environment 100.
  • bridge system 136 may provide a walkway over structure 110.
  • bridge system 136 may be connected to drivable supports 135.
  • drivable supports 135 drive bridge system 136 from one location to another location in manufacturing environment 100.
  • a group of drivable supports 135 may move bridge system 136.
  • three supports, four supports, seven supports, or some other suitable number of drivable supports 135 may move bridge system 136 into place.
  • connection devices 195 may be located on bridge system 136 instead of being located on each of drivable supports 135.
  • bridge system 136 may comprise elongate platform 177 on which connection devices 195 are positioned.
  • connection devices 195 may be equally spaced at fixed intervals along elongate platform 177 or spaced at intervals that may change by moving one or more of connection devices 195.
  • Elongate platform 177 is an elevated platform in this illustrative example. When elongate platform 177 is used, structure 110 is connected to connection devices 195 positioned along elongate platform 177.
  • elongate platform 177 may take the form of a beam. In other illustrative examples, elongate platform 177 may take the form of any physical structure having a shape and size configured to hold and support structure 110.
  • connection devices 195 may be positioned on each platform in various configurations.
  • connection devices 195 may be positioned along the length of elongate platform 177.
  • connection devices 195 may be positioned adjacent to one another along the entire length of elongate platform 177. In this manner, more of connection devices 195 may be implemented in an illustrative embodiment without increasing the number of drivable supports 135 used.
  • Each of connection devices 195 positioned along elongate platform 177 correspond to one or more of connection points 167 of structure 110.
  • each of drivable supports 135 may move a portion of elongate platform 177.
  • each of drivable supports 135 oriented underneath elongate platform 177 may move a point on elongate platform 177 in at least one of the x-direction, the y-direction, or the z-direction.
  • Drivable supports 135 also may rotate a point on elongate platform 177 about the (x-axis, the y-axis, or the z-axis to position elongate platform 177 as desired.
  • drivable support 137 may use a z-ram or other lift device to lift a portion of elongate platform 177 higher above the ground to compensate for uneven areas of floor 107. In this manner, drivable support 137 may move to control the flatness of elongate platform 177 and accordingly, control the position of corresponding portions of structure 110. As another example, drivable support 137 may tilt elongate platform 177 such that connection devices 195 connected to elongate platform 177 bring control points 193 on structure 110 into alignment.
  • connection devices 195 individually to reposition part of structure 110.
  • select connection devices 195, drivable supports 135, portions of elongate platform 177, or some combination thereof may move to precisely position part of structure 110.
  • connection devices 195 may be fixed on elongate platform 177. In such a case, connection devices 195 may not move individually. Instead, drivable supports 135 move elongate platform 177 to properly position structure 110. In other examples, however, one or more of connection devices 195 may move as well.
  • bridge system 136 also may be used to supply a number of utilities 179 to one or more devices in flexible manufacturing system 102.
  • Utilities 179 may include at least one of electricity, water, air, communications, or other utilities.
  • elongate platform 177 may include channel 185.
  • a number of lines 187 may run through channel 185.
  • lines 187 may be structures through which utilities 179 run.
  • some of lines 187 may take the form of cables carrying electricity or communications.
  • lines 187 carry air.
  • lines 187 may be deposited within elongate platform 177, attached underneath elongate platform 177, oriented along elongate platform 177 in some other manner, or a combination thereof.
  • portions of bridge system 136 may come together to support structure 110 using drivable supports 135.
  • a first group of drivable supports 135 may move elongate platform 177 into manufacturing environment 100 to support a leading edge of structure 110.
  • a second group of drivable supports 135 may move a second elongate platform into manufacturing environment 100 to support a trailing edge of structure 110.
  • the first elongate platform and the second elongate platform may be connected using various end supports, latches, locks, mechanical structures, electrical structures, structural members, or other suitable devices.
  • Elongate platform 177 may balance a number of loads applied to connection devices 195 by structure 110 being connected to connection devices 195. In particular, elongate platform 177 may distribute the number of loads along elongate platform 177 to drivable supports 135. In this manner, elongate platform 177 may be referred to as a load-balancing structure.
  • drivable supports 135 may be adjusted to provide desired load handling. For instance, when traveling at an incline in manufacturing environment 100, drivable supports 135 under elongate platform 177 may move elongate platform 177 up or down to compensate for the load of structure 110. As a result, elongate platform 177 may balance the load applied by structure 110 to connection devices 195. Load balancing helps to reduce or eliminate undesired encounters with other objects, inconsistencies forming in floor 107 due to the unbalanced load of structure 110, or other undesired events.
  • rail system 138 may be associated with bridge system 136 and portions of structure 110. Rail system 138 may be configured to provide fall protection 144 for human operator 142. As an example, rail system 138 may provide a barrier such that human operator 142 does not fall off elongate platform 177 in bridge system 136.
  • rail system 138 may be arranged on structure 110 to provide separation between plurality of autonomous tool systems 118 and human operator 142.
  • rail system 138 may be positioned about perimeter 140 of structure 110 to separate plurality of autonomous tool systems 118 from human operator 142.
  • Rail system 138 may be used in addition to, or in place of, other fall protection devices such as cables, grips, ties, suspension devices, and slip protection, among others.
  • drivable support system 116 may carry structure 110 through manufacturing environment 100. In this manner, drivable supports 135 remain connected to structure 110 as structure 110 moves between plurality of work cells 112. No fixed monument structures are needed to hold structure 110 in place within any of plurality of work cells 112. Structure 110 is driven from location to location without detaching structure 110 from drivable support system 116.
  • each of drivable supports 135 may be dynamically adjusted to compensate for various differences in plurality of work cells 112. For instance, one or more of drivable supports 135 may be adjusted to compensate for conditions such as, for example, without limitation, uneven floors, platform deflections, debris, and access requirements for plurality of autonomous tool systems 118, among others. Adjustments may be made to connection devices 195 as well.
  • plurality of autonomous tool systems 118 may be drivable devices configured to perform operations 130 on structure 110.
  • plurality of autonomous tool systems 118 may move freely within manufacturing environment 100 between locations 103 to perform operations 130.
  • Each of plurality of autonomous tool systems 118 may be referred to as mobile tools or automated tools in some cases.
  • Plurality of autonomous tool systems 118 may comprise at least one of a crawler robot, a tack driller, a hexapod, a lower panel driller, an upper panel driller, or some other suitable device.
  • Plurality of autonomous tool systems 118 also may be configured to drive from location to location with drivable support system 116.
  • plurality of autonomous tool systems 118 may drive between plurality of work cells 112 as drivable support system 116 also drives between plurality of work cells 112.
  • plurality of autonomous tool systems 118 includes autonomous tool system 131.
  • Autonomous tool system 131 may have a number of different components in this illustrative example.
  • autonomous tool system 131 may include at least one of a drilling system, a fastening system, a loading system, a measurement device, a coating system, an inspection system, a sealing system, a cleaning system, or other suitable types of devices configured to perform operations 130 on structure 110.
  • Autonomous tool system 131 may take the form of automated guided vehicle 197 (AGV) in some illustrative examples.
  • AGV automated guided vehicle 197
  • plurality of autonomous tool systems 118 may be configured to move between plurality of work cells 112 without human intervention.
  • each of plurality of autonomous tool systems 118 may be capable of communicating with controller 122, navigating through manufacturing environment 100, and performing operations 130 without instructions from human operator 142.
  • Each of plurality of autonomous tool systems 118 may know its position in manufacturing environment 100 relative to other tools, drivable support system 116, structure 110, and other objects.
  • plurality of autonomous tool systems 118 may include first portion 147 and second portion 148.
  • a "portion" of plurality of autonomous tool systems 118 may comprise one or more tools in this illustrative example.
  • operations 130 may be performed on structure 110 in manufacturing environment 100.
  • Operation 139 may be one of operations 130.
  • Operation 139 may be selected from one of a drilling operation, a fastening operation, an inspecting operation, a sealing operation, a measurement operation, a leveling operation, a cleaning operation, and other suitable types of operations.
  • operations 130 may be referred to as assembly operations.
  • Each of plurality of autonomous tool systems 118 may perform one or more of operations 130.
  • a number of operations 130 may be performed in each of plurality of work cells 112.
  • plurality of autonomous tool systems 118 may be configured to operate simultaneously to perform operations 130 on structure 110. As used herein, when plurality of autonomous tool systems 118 perform operations "simultaneously," two or more tools perform operations at substantially the same time.
  • autonomous tool system 131 may drill holes in one portion of structure 110, while another one of plurality of autonomous tool systems 118 may drill holes in a different portion of structure 110.
  • first portion 147 of plurality of autonomous tool systems 118 may perform drilling, measuring, and fastening operations, while second portion 148 of plurality of autonomous tool systems 118 may perform sealing and coating operations.
  • first portion 147 of plurality of autonomous tool systems 118 may be positioned relative to first side 150 of structure 110 to perform drilling operations.
  • second portion 148 of plurality of autonomous tool systems 118 may be positioned relative to second side 151 of structure 110 to perform drilling operations.
  • metrology system 120 may include one or more measurement devices.
  • Metrology system 120 may be configured to generate metrology data 154 for at least one of drivable support system 116, plurality of autonomous tool systems 118, structure 110, or other components within manufacturing environment 100.
  • Metrology data 154 may be referred to as position data or position information in some examples.
  • metrology system 120 may take the form of a photogrammetry system, a laser tracker system, an indoor global positioning system (iGPS), or other suitable types of measurement systems.
  • Metrology system 120 may include plurality of sensor systems 156 in some illustrative examples.
  • a sensor system in plurality of sensor systems 156 may have a number of sensors and other components.
  • Plurality of sensor systems 156 may comprise targets, target systems, transmitters, receivers, transceivers, or other suitable components.
  • some of plurality of sensor systems 156 in metrology system 120 may be connected to drivable supports 135 in drivable support system 116.
  • one of plurality of sensor systems 156 may be mounted on each of drivable supports 135 or secured to drivable supports 135 in some other manner.
  • metrology system 120 may track drivable support system 116 as drivable support system 116 moves.
  • elongate platform 177 in bridge system 136 is implemented in an illustrative embodiment, some of plurality of sensor systems 156 are connected to elongate platform 177. These sensors may be used to determine the flatness of elongate platform 177.
  • Plurality of sensor systems 156 also may be connected to structure 110 in this illustrative example. For instance, some of plurality of sensor systems 156 may be positioned on first side 150 or second side 151 of structure 110 to serve as reference locations for metrology system 120. In other examples, one or more of plurality of sensor systems 156 are positioned at each of control points 193 on structure 110.
  • plurality of sensor systems 156 also may be positioned on each of plurality of autonomous tool systems 118.
  • Metrology system 120 may scan plurality of sensor systems 156 using at least one of a laser, a camera, or some other suitable device to generate metrology data 154.
  • metrology data 154 may include data that indicates the location and orientation of an object in three-dimensional space.
  • metrology data 154 may include coordinates 160 of an object associated with one of plurality of sensor systems 156.
  • Coordinates 160 may include Cartesian coordinates for the object in global coordinate system 181.
  • metrology system 120 may generate coordinates 160 for autonomous tool system 131.
  • metrology system 120 may generate coordinates 160 for a point on the surface of elongate platform 177.
  • metrology system 120 may generate coordinates 160 for a portion of structure 110. From coordinates 160, as well as any orientation information contained in metrology data 154, position 162 of structure 110 may be adjusted to desired position 133.
  • Metrology system 120 may provide feedback control 199 for flexible manufacturing system 102 based on metrology data 154. For instance, metrology system 120 may locate at least one of drivable supports 135, points on elongate platform 177, plurality of autonomous tool systems 118, control points 193 of structure 110, or other components. After locating these components, drive control system 121 may reconfigure one or more of these components as desired.
  • drive control system 121 comprises various components used to control movement and may include controller 122, navigator 124, and transformer 126.
  • Controller 122, navigator 124, and transformer 126 each may be implemented in software, hardware, firmware, or a combination thereof.
  • controller 122, navigator 124, or transformer 126 When software is used, the operations performed by any one of controller 122, navigator 124, or transformer 126 may be implemented using, for example, without limitation, program code configured to run on a processor unit. When firmware is used, the operations performed by any one of controller 122, navigator 124, or transformer 126 may be implemented using, for example, without limitation, program code and data and stored in persistent memory to run on a processor unit.
  • the hardware may include one or more circuits that operate to perform the operations performed by any one of controller 122, navigator 124, or transformer 126.
  • the hardware may take the form of a circuit system, an integrated circuit, an application specific integrated circuit (ASIC), a programmable logic device, or some other suitable type of hardware device configured to perform any number of operations.
  • ASIC application specific integrated circuit
  • the device may be configured to perform the number of operations.
  • the device may be reconfigured at a later time or may be permanently configured to perform the number of operations.
  • programmable logic devices include, for example, a programmable logic array, a programmable array logic, a field programmable logic array, a field programmable gate array, and other suitable hardware devices.
  • the processes may be implemented in organic components integrated with inorganic components and may be comprised entirely of organic components excluding a human being.
  • the processes may be implemented as circuits in organic semiconductors.
  • the operations, processes or both performed by controller 122, navigator 124, or transformer 126 may be performed using organic components integrated with inorganic components. In some cases, the operations, processes, or both may be performed entirely by organic components, excluding a human being. As one illustrative example, circuits in organic semiconductors may be used to perform these operations, processes, or both.
  • controller 122 may be implemented in computer system 164.
  • Navigator 124, transformer 126, or both also may be implemented in computer system 164.
  • Computer system 164 may be one or more computers. When more than one computer is present in computer system 164, the computers may communicate with each other over a communications medium such as a network.
  • each of controller 122, navigator 124, and transformer 126 are implemented in separate computer systems.
  • controller 122 may be a device configured to control operation of plurality of autonomous tool systems 118 using metrology data 154. Controller 122 may be in communication with metrology system 120, plurality of autonomous tool systems 118, and other components within flexible manufacturing system 102.
  • controller 122 may communicate with metrology system 120 wirelessly over a network.
  • controller 122 may communicate with other components via a wired connection.
  • controller 122 may be configured to send commands 166 to various components within flexible manufacturing system 102.
  • commands 166 may include navigation instructions, operation instructions, steering, position instructions, and other suitable types of instructions.
  • controller 122 may send commands 166 to drivable support system 116 to change position 162 of structure 110 based on metrology data 154 generated by metrology system 120. For instance, commands 166 may be sent to drivable support system 116 when position 162 of structure 110 has deviated from desired position 133. In this case, one or more of drivable supports 135, connection devices 195, or both may actuate to move structure 110 to desired position 133 based on commands 166. After structure 110 is moved, metrology system 120 may again determine position 162 of structure 110 to provide feedback control 199.
  • Controller 122 also may be configured to send commands 166 to plurality of autonomous tool systems 118 in this illustrative example.
  • controller 122 may be configured to assign tasks 111 to plurality of autonomous tool systems 118 in commands 166 sent to plurality of autonomous tool systems 118.
  • Each of tasks 111 may include one or more operations 130.
  • controller 122 may be configured to monitor status 170 of tasks 111 assigned to plurality of autonomous tool systems 118 and status 172 of plurality of autonomous tool systems 118.
  • status 170 of tasks 111 may be a state of tasks 111.
  • status 170 may represent the number of tasks 111 that have been completed by plurality of autonomous tool systems 118.
  • Status 170 also may include an indication of a level of completion for tasks 111. In some cases, some of tasks 111 may be performed substantially concurrently or may overlap in time.
  • Status 170 may include a numerical value in some illustrative examples. For instance, status 170 may indicate that fifty percent of tasks 111 are complete. In another example, status 170 may indicate the number of holes left to be drilled. In still another illustrative example, status 170 may be at least one of "complete,” "in-progress,” or other suitable states of tasks 111.
  • status 172 may be an indicator of the state of each of plurality of autonomous tool systems 118.
  • status 172 may indicate whether each one of plurality of autonomous tool systems 118 is online, offline, in a standby mode, in-route, or in other states of operation.
  • status 172 may indicate which one of operations 130 is being performed. As an example, status 172 may indicate that inspection of a hole is being performed. In another example, status 172 may indicate that a fastener is being installed. In still another illustrative example, status 172 may indicate that autonomous tool system 131 is currently changing tools.
  • controller 122 may be configured to reassign tasks 111 between plurality of autonomous tool systems 118 based on at least one of status 170 of tasks 111 or status 172 of plurality of autonomous tool systems 118. As an example, controller 122 may reassign tasks 111 when autonomous tool system 131 goes offline. In this manner, assembly of wing 108 is not interrupted by autonomous tool system 131 going offline.
  • controller 122 may reassign tasks 111 when some of tasks 111 are complete. As a result, controller 122 may efficiently allocate resources within flexible manufacturing system 102. In assigning and reassigning tasks 111 to plurality of autonomous tool systems 118, controller 122 may be configured to change position 174 of each of plurality of autonomous tool systems 118 based on metrology data 154 generated by metrology system 120. In particular, path 176 may be generated for each of plurality of autonomous tool systems 118 based on metrology data 154.
  • navigator 124 is a component in drive control system 121 that may be configured to generate path 176 for each of plurality of autonomous tool systems 118 to perform operations 130. Navigator 124 may be referred to as a navigation system in some instances.
  • path 176 may be a route through manufacturing environment 100.
  • path 176 may be a route for autonomous tool system 131 to get from second location 115 to third location 117 to perform operations 130.
  • Path 176 may be generated and modified for each of plurality of autonomous tool systems 118 in real-time. Path 176 may change as metrology system 120 continuously locates the components in manufacturing environment 100 to provide feedback control 199.
  • path 176 may be generated to avoid undesired encounters between autonomous tool system 131 and other objects in manufacturing environment 100, falls from structure 110, or other undesired events.
  • navigator 124 may generate path 176 in the form of a set of instructions, waypoints, or other information usable by autonomous tool system 131.
  • transformer 126 may be in communication with navigator 124, metrology system 120, and controller 122. In some cases, such as when transformer 126 is implemented in hardware, transformer 126 may be referred to as a transformation device.
  • Transformer 126 may be configured to transform metrology data 154 generated by metrology system 120 to airplane coordinates 178 in airplane coordinate system 183. In this manner, transformer 126 transforms coordinates 160 to airplane coordinates 178 usable to move plurality of autonomous tool systems 118 relative to structure 110.
  • Airplane coordinate system 183 may represent a reference coordinate system in which airplane parts are located in three-dimensional space. Airplane coordinate system 183 may be based on an origin or reference point in aircraft 109.
  • Path 176 may be generated by navigator 124 based on airplane coordinates 178 received from transformer 126 such that autonomous tool system 131 moves to a desired location relative to structure 110.
  • one or more components in drive control system 121 may be remote to one another.
  • controller 122 may be remote to flexible manufacturing system 102.
  • loading system 127 may be a structure configured to position at least one of first skin panel 180 or second skin panel 182 relative to structure 110.
  • first skin panel 180 may take the form of upper skin panel 184 for wing 108.
  • Second skin panel 182 may take the form of lower skin panel 186 for wing 108.
  • loading system 127 may comprise first loading device 188 and second loading device 190.
  • First loading device 188, second loading device 190, or both may be selected from one of a loading platform, an elevator, a track system, a robotic arm, a gantry, and other suitable types of devices.
  • Metrology system 120 may locate first loading device 188 and second loading device 190 to provide feedback control 199 as these devices are moved from location to location.
  • first loading device 188 may be configured to position upper skin panel 184 relative to structure 110. For instance, first loading device 188 may place upper skin panel 184 on first side 150 of structure 110. Operations 130 may then be performed on upper skin panel 184 by plurality of autonomous tool systems 118.
  • second loading device 190 may be configured to position lower skin panel 186 relative to structure 110.
  • second loading device 190 may place lower skin panel 186 on second side 151 of structure 110.
  • Operations 130 may be performed on lower skin panel 186 by plurality of autonomous tool systems 118.
  • steering direction 196 may be provided for various components in flexible manufacturing system 102.
  • steering direction 196 may be provided for plurality of autonomous tool systems 118, drivable support system 116, each of drivable supports 135, and other devices moving from location to location in manufacturing environment 100.
  • Steering direction 196 may take the form of commands, instructions, path generation, physically changing the direction of movement of the device, and other methods of guidance.
  • steering direction 196 may dynamically change as conditions within manufacturing environment 100 change.
  • Steering direction 196 may be provided by at least one of controller 122, human operator 142, or some other suitable device. In other illustrative examples, each steerable device may steer itself, not under the direction of a controller.
  • controller 122 may send commands 166 to steer autonomous tool system 131.
  • human operator 142 may steer drivable support 137 by physically changing its direction.
  • the reconfigurability of flexible manufacturing system 102 may allow operations 130 to be performed in an efficient manner, without undesired intervention by human operators. Controller 122 may control operation of all of the components in flexible manufacturing system 102 at the same time, taking into account the position and status of one another. Feedback control 199 provided by metrology system 120 allows for coordinated control of flexible manufacturing system 102. As a result, plurality of autonomous tool systems 118 may work simultaneously to assemble wing 108.
  • each of the components within flexible manufacturing system 102 may be reconfigured depending on the size of manufacturing environment 100. Without the use of fixed monument fixtures, flexible manufacturing system 102 may provide a more efficient way of assembling wing 108 than some currently used systems.
  • drivable supports 135 may comprise lighter materials or fewer materials than a fixed monument fixture. As a result, drivable supports 135 may be lighter and cost less.
  • the use of elongate platform 177 may require fewer sensors to accurately locate and adjust the position of structure 110. For example, without limitation, instead of positioning one of plurality of sensor systems 156 on each of control points 193, connection devices 195, or both, several sensors can be placed on the surface of elongate platform 177 to determine its flatness. One or more portions of elongate platform 177 is then adjusted to bring structure 110 into alignment. The use of fewer sensors may further reduce up-front set up costs.
  • more than one of structure 110 may be present in manufacturing environment 100 at the same time.
  • components may be added to each structure 110 simultaneously to form multiple wings.
  • the ability to reconfigure plurality of autonomous tool systems 118 may allow the same set of tools to be used on multiple wing assemblies at the same time, increasing the rate of production of wings for aircraft.
  • each of plurality of autonomous tool systems 118 may include a sensor system configured to generate position information, measure depth of holes, or perform other processes.
  • each of the components within flexible manufacturing system 102 may comprise a separate controller configured to control operations of that particular device.
  • Each of these controllers may communicate with controller 122.
  • plurality of autonomous tool systems 118 work in tandem with human operators within manufacturing environment 100.
  • a number of human operators may be present in plurality of work cells 112 to oversee progress of flexible manufacturing system 102, perform additional operations 130, or for some other reason.
  • flexible manufacturing system 102 may include a movement system.
  • This movement system may be configured to move drivable support system 116 between plurality of work cells 112.
  • the movement system may include a track system, wheels, a tug, an automated guided vehicle (AGV), or some other suitable type of movement device.
  • the movement system may be integrated in drivable support system 116 and retract when drivable support system 116 reaches its destination within a work cell.
  • additional sensor systems may be employed to generate various types of information with respect to the components in flexible manufacturing system 102, structure 110, or both.
  • force sensors also referred to as load sensors
  • load sensors may be used in load balancing.
  • load sensors may be implemented at various points along the length of elongate platform 177 to determine loads applied to elongate platform 177 by structure 110. From this sensor feedback, elongate platform 177 may be moved such that overloading does not occur.
  • manufacturing environment 200 with work cells 202 may be an example of a physical implementation for manufacturing environment 100 with plurality of work cells 112 shown in block form in Figure 1 .
  • wing assemblies 204 may move through work cells 202.
  • Each of wing assemblies 204 may be an example of a physical implementation for structure 110 in Figure 1 .
  • operations may be performed on wing assemblies 204 to form wings for an aircraft (not shown in this view).
  • manufacturing environment 200 may include flexible manufacturing system 206 to perform operations on wing assemblies 204.
  • Flexible manufacturing system 206 may provide pulsed continuous movement of wing assemblies 204. Pulsed continuous movement may be movement from one of work cells 202 to another one of work cells 202, stopping within each work cell temporarily for operations to be performed.
  • Flexible manufacturing system 206 may include drivable support system 208, autonomous tool systems 210, metrology system 212, and system controller 214.
  • Drivable support system 208, autonomous tool systems 210, metrology system 212, and system controller 214 may be examples of physical implementations for drivable support system 116, plurality of autonomous tool systems 118, metrology system 120, and controller 122 shown in block form in Figure 1 .
  • Flexible manufacturing system 206 may move throughout manufacturing environment 200 between work cells 202. In this manner, components may move from location to location in work cells 202 to perform operations on any one of wing assemblies 204.
  • Flexible manufacturing system 206 also may be reconfigurable based on the layout and size of manufacturing environment 200, the size and manufacturing needs of wing assemblies 204, and other suitable parameters.
  • a wing assembly (not shown in this view) may move between work cell 216, work cell 218, work cell 220, work cell 222, and work cell 224 as operations are being performed.
  • the wing assembly may be carried between these work cells by various components in flexible manufacturing system 206.
  • components within flexible manufacturing system 206 drive from work cell to work cell to move with the wing assembly in this illustrative example.
  • Figures 3-16 show the progression of an assembly process using flexible manufacturing system 206 in manufacturing environment 200 from Figure 2 .
  • Figures 3- 16 show a wing assembly moving through various work cells 202.
  • FIG. 3 an illustration of a work cell with wing assembly components staged for installation is depicted in accordance with an illustrative embodiment.
  • work cell 216 is shown.
  • components for wing assembly 302 may be present in work cell 216.
  • structural members 304 for wing assembly 302 may be present in work cell 216.
  • Wing assembly 302 may be an example of a physical implementation for structure 110 shown in Figure 1 .
  • structural members 304 may be staged.
  • Structural members 304 may be units that provide structural support and load handling capability for a wing (not shown).
  • Structural members 304 may include spars 306 and ribs 308 in this illustrative example. Additionally, a number of adapter fittings, hinges, and other components may be staged in work cell 216.
  • FIG 4 an illustration of drivable support system 208 from Figure 2 positioned in a work cell is depicted in accordance with an illustrative embodiment.
  • drivable support system 208 is positioned in work cell 218.
  • drivable support system 208 may include supports 402.
  • Supports 402 may be an example of a physical implementation for drivable supports 135 shown in block form in Figure 1 .
  • Each of supports 402 drives from location to location within manufacturing environment 200.
  • supports 402 come together to form drivable support system 208, supports 402 move collectively from work cell to work cell as operations are performed on wing assembly 302.
  • each of supports 402 may be moved from another location in manufacturing environment 200 to reach work cell 218.
  • each of supports 402 may be moved and arranged relative to one another to form drivable support system 208, a non-fixed fixture.
  • a platform (not shown in this view) may connect supports 402 to one another in some illustrative examples.
  • each of supports 402 may be interchangeable.
  • supports 402 may be capable of being used in place of one another. In this manner, reconfiguring supports 402 may be done more quickly than if supports 402 had to be arranged in a particular order.
  • Supports 402 bring parts (not shown) of wing assembly 302 together from various locations in manufacturing environment 200. As an example, one of supports 402 may bring a portion of wing assembly 302 from work cell 216, while another one of supports 402 may bring a different portion of wing assembly 302 from work cell 216. In another illustrative example, supports 402 may be arranged first and then wing assembly 302 may be connected to supports 402 thereafter. Each of supports 402 may have connection devices (not shown) that are connected to a different portion of wing assembly 302 at different control points (not shown).
  • some of supports 402 may be brought together to form drivable support system 208 and carry wing assembly 302 from one location to a second location in manufacturing environment 200.
  • other supports 402 may be brought together into another type of non-fixed fixture, or second drivable support system, to carry another portion of wing assembly 302 from yet another location in manufacturing environment 200 to the second location or some other location.
  • drivable support system 208 and the second drivable support system may combine into a new collective to form a new non-fixed fixture.
  • additional supports 402 may be added or removed as desired, bringing parts to wing assembly 302 at various locations.
  • the illustrative embodiments allow several collectives of supports 402 to come together at different points and times during the assembly process to form new non-fixed fixtures bringing the assemblies they carry into inclusion in a larger overarching assembly.
  • Support 403 may be an example of one of supports 402.
  • Support 403 may be a module that is interchangeable with other supports 402 in this illustrative example.
  • supports 402 may be arranged adjacent to one another within work cell 218.
  • First portion 404 of supports 402 may be positioned opposite second portion 406 of supports 402 to hold wing assembly 302 in a horizontal configuration.
  • wing assembly 302 may be received by drivable support system 208.
  • Wing assembly 302 may be moved in the direction of arrow 414 to be received by drivable support system 208.
  • a group of supports 402 may pick up a portion of wing assembly 302 and bring it to work cell 218, much like a human operator would bring different parts to the assembly to facilitate attachment of those parts.
  • FIG. 5 an illustration of drivable support system 208 with wing assembly 302 from Figure 4 is depicted in accordance with an illustrative embodiment. Wing assembly 302 has been driven in the direction of arrow 414.
  • first portion 404 of supports 402 may hold side 500 of wing assembly 302.
  • second portion 406 may hold side 502 of wing assembly 302.
  • Supports 402 may be adjusted vertically in the direction of arrow 503 to accommodate a desired height for wing assembly 302. The desired height may change between work cells 202, depending on the type of operations being performed.
  • each of supports 402 may be secured to wing assembly 302 at different points along side 500 and side 502 of wing assembly 302.
  • Supports 402 may be connected to wing assembly 302 using any mechanical method configured to hold wing assembly 302 in a desired manner.
  • supports 402 may clamp wing assembly 302 in position using connection devices (not shown).
  • bridge system 504 has been connected to drivable support system 208.
  • Human operators 506 may use bridge system 504 to access and view wing assembly 302.
  • Bridge system 504 and human operators 506 may be examples of physical implementations for bridge system 136 and human operator 142 shown in block form in Figure 1 .
  • rail system 508 may be associated with bridge system 504.
  • Rail system 508 may be an example of a physical implementation for rail system 138 shown in block form in Figure 1 .
  • Rail system 508 may include rails 510 on bridge system 504. Rails 510 may reduce the risk of human operators 506 falling off bridge system 504. In this manner, rail system 508 may provide fall protection for human operators 506.
  • wing assembly 302 may be in work cell 218.
  • ribs 308 may be drilled and fastened.
  • wing assembly 302 may be scanned by metrology system 212 to analyze the position of structural members 304 in wing assembly 302.
  • Metrology system 212 relies on various sensors (not shown in this view) to determine the position of structural members 304.
  • System controller 214 may be in communication with metrology system 212 and compare the position of structural members 304 to a desired position. Adjustments may be made in response to this comparison. Metrology system 212 may provide feedback control as the adjustments are made until a desired position is reached.
  • wing assembly 302 may be leveled and a front spar hinge line may be set. Panel 512 may then be positioned relative to side 514 of wing assembly 302. Panel 512 may be an example of a physical implementation for upper skin panel 184 shown in Figure 1 . Panel 512 is moved in the direction of arrow 414 to be placed on top of wing assembly 302 in this illustrative example.
  • FIG. 6 an illustration of wing assembly 302 and drivable support system 208 shown in the direction of lines 6-6 in Figure 5 is depicted in accordance with an illustrative embodiment.
  • Bridge system 508 has been removed such that components within drivable support system 208 may be seen in greater detail.
  • platform 600 may be a continuous platform in this illustrative example.
  • Tow gate 602 also may be added to connect first portion 404 of supports 402 with second portion 406 of supports 402. Tow gate 602 may be configured to connect to a tug or other movement system to move drivable support system 208 between work cells 202 shown in Figure 2 .
  • human operators 506 may move about work cell 218. Human operators 506 may monitor the assembly process for wing assembly 302, perform operations, or both. In this illustrative example, human operators 506 may have access to all portions of wing assembly 302.
  • FIG. 7 an illustration of a loading device loading a panel on wing assembly 302 from Figure 6 is depicted in accordance with an illustrative embodiment.
  • loading device 700 has moved panel 512 in the direction of arrow 414 in Figure 6 .
  • Loading device 700 may be an example of a physical implementation for first loading device 188 shown in block form in Figure 1 .
  • Loading device 700 may place panel 512 on side 514 of wing assembly 302 in this illustrative example. Operations may then be performed on panel 512.
  • rails 702 may be positioned on panel 512 of wing assembly 302. Rails 702 may be part of rail system 508 and may be configured to reduce the risk of human operators 506 falling from wing assembly 302. Rails 702 also may separate human operators 506 from undesired encounters with autonomous tool systems 210 shown in Figure 2 .
  • FIG 8 an illustration of a portion of autonomous tool systems 210 from Figure 2 performing operations on panel 512 from Figure 7 is depicted in accordance with an illustrative embodiment.
  • a portion of autonomous tool systems 210 may be deployed onto surface 800 of panel 512.
  • drilling devices 802 may be deployed on surface 800 of panel 512.
  • Drilling devices 802 may be examples of physical implementations for plurality of autonomous tool systems 118 shown in block form in Figure 1 .
  • Drilling devices 802 may take the form of tack drillers in this illustrative example.
  • drilling devices 802 may be autonomous devices configured to drill holes in panel 512 and install tack fasteners (not shown in this view). These tack fasteners provide clamp up at select locations to help mitigate shimming, misalignment, or other issues for structural members 304 shown in Figures 3-6 .
  • Tack driller 804 shown in section 806 of wing assembly 302 may be one of drilling devices 802.
  • drilling devices 802 may move about surface 800 of panel 512 at the same time, performing drilling and fastening operations simultaneously at different locations on panel 512.
  • Drilling devices 802 communicate with system controller 214 shown in Figure 2 . Specifically, drilling devices 802 may receive instructions from system controller 214. These instructions may include a path of movement and the different operations to be performed.
  • Position feedback may be generated about each of drilling devices 802. This feedback may be generated by metrology system 212, active components on drilling devices 802, or a combination thereof. For instance, as drilling devices 802 move about panel 512, drilling devices 802 may continuously provide feedback to system controller 214. This feedback may include position information, status, results of an inspection performed on panel 512, and other suitable information.
  • System controller 214 uses this feedback to reposition drilling devices 802, to ensure holes are drilled in the correct location, to avoid collisions between drilling devices 802, and to more efficiently assign tasks between drilling devices 802.
  • each of drilling devices 802 may move along surface 800 of panel 512 without undesired encounters with one another or human operators 506, falling off wing assembly 302, drilling holes in undesired locations, or a combination thereof.
  • human operators 506 may perform additional operations on panel 512.
  • human operators 506 may locate, drill, and install components on the underside (not shown) of panel 512. These components may include shear ties, stringer end fittings, disbond arrest fasteners, and other suitable components.
  • other autonomous tool systems 210 may install these components.
  • additional components may be included in work cell 218.
  • a counterbalance system (not shown in this view) may be connected to each of drilling devices 802.
  • the counterbalance system may be configured to offset the weight of one of drilling devices 802.
  • the counterbalance system may be removably attached to tack driller 804 and may include pulleys, weights, connectors, cables, and other components.
  • drilling devices 802 may be removed from surface 800 of panel 512. Panel 512 may then be unloaded by loading device 700 for deburring, cleaning, and sealing (removal not shown in this view).
  • drivable support system 208 with wing assembly 302 may be moved to work cell 220 as shown in Figure 10 .
  • Drivable support system 208 with wing assembly 302 may be moved in the direction of arrow 808 to work cell 220.
  • tack driller 804 may move along surface 800 of panel 512 using movement system 900.
  • Tack driller 804 may have on-board controller 902.
  • On-board controller 902 communicates with system controller 214 shown in Figure 2 and receives instructions to navigate surface 800 of panel 512.
  • On-board controller 902 for tack driller 804 may establish a local coordinate system by synchronizing on magnets that are pre-installed in wing assembly 302.
  • Tool 904 on tack driller 804 may be used to drill holes and insert the tack fasteners. Human operators 506 may manually install a nut on each tack fastener and tighten within selected tolerances.
  • system controller 214 may control movement of drilling devices 802, including tack driller 804, to avoid human operators 506.
  • drilling devices 802 are taken offline completely.
  • rail system 508 is modified to separate drilling devices 802 from human operators 506.
  • other safety measures may be provided. For instance, a group of proximity sensors may be used to sense human operators 506 and adjust the behavior of drilling devices 802 accordingly.
  • FIG 10 an illustration of autonomous tool systems 210 performing operations on panel 512 from Figure 8 is depicted in accordance with an illustrative embodiment.
  • Drivable support system 208 with wing assembly 302 has been moved in the direction of arrow 808 to work cell 220.
  • Work cell 220 may be an example of a physical implementation for one of plurality of work cells 112 shown in Figure 1 .
  • crawler robots 1001 may be placed on surface 800 of panel 512 by crawler support 1002.
  • Crawler support 1002 may include drivable platforms in this illustrative examples. In other cases, when used with autonomous tool systems other than crawler robots 1001, crawler support 1002 may be referred to as autonomous tool system support. These drivable platforms may be configured to drive across the floor of manufacturing environment 200 and place the group of crawler robots 1001 on surface 800 of the structure, in this case, panel 512.
  • Crawler robots 1001 with crawler support 1002 may be examples of physical implementations for plurality of autonomous tool systems 118 in Figure 1 .
  • Each of crawler robots 1001 may include a flextrack system in this illustrative example.
  • crawler robots 1001 may correspond to one of crawler support 1002 in this illustrative example.
  • crawler support 1002 may provide power, move utility cables, or assist crawler robots 1001 with other processes.
  • Crawler robot 1004 and drivable platform 1006 are shown in section 1008 of wing assembly 302.
  • crawler robots 1001 may be autonomous devices configured to drill countersunk holes in panel 512, inspect the holes and the countersink depth of those holes, install fasteners (not shown in this view), and inspect the installed fasteners. These fasteners may be interference fit fasteners in this illustrative example.
  • an "interference fit" fastener may have a shank with a diameter that is greater than the diameter of the cylindrical portion of the hole in which it is installed. Friction between the post and the cylindrical portion of the hole holds the fastener in place.
  • the interference fit of the fastener may increase the fatigue life of the parts that the fastener is connecting, namely, panel 512 and its substructure.
  • the interference fit fastener also may substantially prevent fastener movement relative to the hole.
  • crawler robots 1001 may move about surface 800 of panel 512 at the same time, performing drilling and fastening operations simultaneously at different locations on panel 512.
  • Crawler robots 1001 may communicate with system controller 214 shown in Figure 2 .
  • crawler robots 1001 may receive instructions from system controller 214. These instructions may include a path of movement and the different operations to be performed. Throughout movement, crawler robots 1001 may continuously provide feedback to system controller 214. This feedback may include position information, status, results of inspection performed on panel 512, and other suitable information.
  • System controller 214 uses this feedback to reposition crawler robots 1001, to ensure holes are drilled in the correct location, to avoid collisions between crawler robots 1001, and to more efficiently assign tasks between crawler robots 1001.
  • each of crawler robots 1001 may move along surface 800 of panel 512 without undesired encounters with one another or human operators 506, falling off wing assembly 302, or both.
  • the feedback increases accuracy of operations performed by crawler robots 1001.
  • Feedback also may be provided by metrology system 212 as metrology system 212 scans manufacturing environment 200, as described above.
  • Crawler robots 1001 may be configured to provide "one-up assembly" of fasteners in panel 512.
  • "one-up" assembly may refer to the process of drilling and fastening joints without having to disassemble parts for cleaning or deburring.
  • One-up assembly may increase the speed at which wings are manufactured.
  • crawler robots 1001 include crawler robot 1004.
  • crawler robot 1004 may be removed using drivable platform 1006.
  • Wing assembly 302 with drivable support system 208 may be moved in the direction of arrow 1010 to work cell 222 as shown in Figure 12 .
  • FIG 11 shows an illustration of section 1008 of wing assembly 302 with crawler robot 1004 and drivable platform 1006 from Figure 10 in accordance with an illustrative embodiment.
  • crawler robot 1004 may be equipped with movement system 1100, movement system 1101, and tools 1102.
  • movement system 1100 may comprise wheels that move crawler robot 1004 along surface 800 of panel 512. These wheels may be retractable in some illustrative examples.
  • Movement system 1101 may include a track system in this illustrative example. Movement system 1101 may be configured to move crawler robot 1004 back and forth in the direction of arrow 1104.
  • tools 1102 may include at least one of an inspection system, a fastener system, a drilling system, a positioning system, or other suitable tools.
  • Crawler robot 1004 also may include on-board controller 1106 in communication with system controller 214 in
  • Drivable platform 1006 may have pick and place arm 1108 and utility arm 1110 in this illustrative example.
  • Pick and place arm 1108 may place crawler robot 1004 onto surface 800 of wing assembly 302.
  • Utility arm 1110 may move utility cables (not shown in this view) that may be attached to crawler robot 1004. These utility cables may supply tools 1102 with at least one of electricity, air supply, communications, or other desirable utilities.
  • counterbalance system 1112 may be associated with utility arm 1110 and connected to crawler robot 1004. Counterbalance system 1112 may be configured to offset the weight of crawler robot 1004 on panel 512. Counterbalance system 1112 may be removably attached to crawler robot 1004 in this illustrative example.
  • counterbalance system 1112 may comprise cable 1113, pulley 1114 attached to utility arm 1110 and weight 1116.
  • Weight 1116 may be less than or equal to the weight of crawler robot 1004.
  • Counterbalance system 1112 with weight 1116 reduces the risk of inconsistencies forming in panel 512 that could be caused by the weight of crawler robot 1004.
  • other counterbalance systems may be possible.
  • FIG. 12 an illustration of a loading device with a panel is depicted in accordance with an illustrative embodiment.
  • loading device 1200 is shown carrying panel 1202 for wing assembly 302.
  • Wing assembly 302 and drivable support system 208 have been moved in the direction of arrow 1010 to work cell 222.
  • Loading device 1200, panel 1202, and work cell 222 may be examples of physical implementations for second loading device 190, lower skin panel 186, and one of plurality of work cells 112, respectively, shown in block form in Figure 1 .
  • loading device 1200 may move panel 1202 in the direction of arrow 1206 to position panel 1202 under wing assembly 302. Loading device 1200 may then lift panel 1202 into a desired position relative to side 1208 of wing assembly 302.
  • Assembly systems 1210 may include a lower panel tool system in this illustrative example. This lower panel tool system may take the form of a lower panel driller.
  • loading device 1200 may comprise platform 1300, movement system 1302, and movement system 1304.
  • platform 1300 may be a structure configured to provide support for movement system 1304 and panel 1202.
  • Movement system 1302 may be a number of components configured to move loading device 1200 with panel 1202 about manufacturing environment 200.
  • movement system 1302 may include at least one of a track system, mecanum wheels, omni wheels and other types of omni-directional wheels, retractable wheels, a gantry system, a tug, or some other suitable movement device.
  • movement system 1304 may be a group of devices configured to move panel 1202 up and down in the direction of arrow 1306.
  • a "group of" items may be one or more items.
  • a group of devices may include one or more devices.
  • movement system 1304 may position panel 1202 relative to side 1208 of wing assembly 302 in Figure 12 .
  • Position feedback may be generated for the components within loading device 1200, panel 1202, or both, as described above.
  • Movement system 1304 may be a lift in this illustrative example. This lift may be a hydraulic lift, a pneumatic lift, or some other suitable type of lift. In particular, movement system 1304 may employ a scissor jack, a bottle jack, and other suitable types of lifts. In some cases, movement system 1304 also may be configured to tilt panel 1202 as needed. Movement system 1304 may provide crude positioning of panel 1202 relative to wing assembly 302 (not shown in this view).
  • movement system 1304 may include repositionable headers 1308.
  • Repositionable headers 1308 may contact panel 1202.
  • repositionable headers 1308 may be structures configured to position panel 1202 in a desired manner. Repositionable headers 1308 may provide more precise positioning for panel 1202 relative to wing assembly 302.
  • utility cable 1310 may be used to connect loading device 1200 with various utilities.
  • utility cable 1310 may be used to provide electricity to loading device 1200.
  • Utility cable 1310 also may provide a communications link between system controller 214 and loading device 1200 for command and control of loading device 1200.
  • FIG. 14 an illustration of assembly systems 1210 performing operations on panel 1202 from Figure 12 is depicted in accordance with an illustrative embodiment.
  • loading device 1200 has moved panel 1202 in the direction of arrow 1206.
  • operations may have been performed on panel 1202 to secure panel 1202 to side 1208 of wing assembly 302.
  • tack drilling and fastening may have been performed to hold panel 1202 in place relative to side 1208 of wing assembly 302.
  • assembly systems 1210 may be deployed under panel 1202.
  • Assembly systems 1210 may be an example of a physical implementation for plurality of autonomous tool systems 118 shown in block form in Figure 1 .
  • Assembly systems 1210 may include a hexapod in this illustrative example.
  • assembly systems 1210 may be autonomous devices configured to perform operations on panel 1202.
  • assembly systems 1210 may clamp structures, drill holes, measure holes, install fasteners, seal fasteners, and perform other types of operations on panel 1202.
  • assembly systems 1210 may move under panel 1202 in the direction of arrow 1206 to perform these operations.
  • assembly system 1400 and one of assembly systems 1210 moves under panel 1202 in the direction of arrow 1206 to perform such operations.
  • system controller 214 communicates with drivable support system 208 to move wing assembly 302 vertically in the direction of arrow 503 as needed.
  • each of assembly systems 1210 may move under panel 1202 at the same time, performing drilling and fastening operations simultaneously at different locations along panel 1202.
  • Assembly systems 1210 may communicate with system controller 214 shown in Figure 2 .
  • Assembly systems 1210 may receive instructions from system controller 214 and provide feedback to system controller 214. Metrology system 212 also may provide feedback to locate each of assembly systems 1210. In this manner, system controller 214 may tightly control the operations of assembly systems 1210. Each of assembly systems 1210 may move under panel 1202 without undesired encounters with one another or human operators, movement beyond the work area, or both.
  • assembly systems 1210 may perform drilling and fastening operations in more than one of work cells 202. For instance, assembly systems 1210 may drill a first portion of the holes needed in panel 1202 (not shown). After the first portion is drilled, panel 1202 may need to be lowered from side 1208 of wing assembly 302 to be cleaned and deburred.
  • panel 1202 may then be reattached to wing assembly 302 and a second portion of the holes may be drilled in panel 1202.
  • Assembly systems 1210 may perform one-up assembly on the remaining fasteners for the second portion of the holes. In other cases, operations may be performed by assembly systems 1210 in some other manner, depending on the particular implementation.
  • drivable support system 208 with wing assembly 302 may move to work cell 224 shown in Figure 16 .
  • Drivable support system 208 with wing assembly 302 may move in the direction of arrow 1404 to work cell 224 in this illustrative example.
  • FIG 15 an illustration of assembly system 1400 performing operations on a surface of wing assembly 302, shown in the direction of lines 15-15 in Figure 14 , is depicted in accordance with an illustrative embodiment.
  • assembly system 1400 has moved in the direction of arrow 1206 in Figure 14 to be positioned relative to surface 1500 of panel 1202.
  • assembly system 1400 may be equipped with movement system 1502, motion platform 1504, and tools 1506 on end effector 1508.
  • Movement system 1502 may move assembly system 1400 into a desired area.
  • Motion platform 1504 then may be used to precisely position end effector 1508 with tools 1506 relative to surface 1500 of panel 1202.
  • Assembly system 1400 may include on-board controller 1510 configured to communicate with system controller 214 in Figure 2 . As assembly system 1400 moves, assembly system 1400 may provide position feedback to system controller 214. Metrology system 212 also may track the position of assembly system 1400.
  • movement system 1502 may comprise wheels that move assembly system 1400 under surface 1500 of panel 1202. These wheels may be retractable once assembly system 1400 is in a desired position.
  • Motion platform 1504 may provide seven degrees of freedom of movement for tools 1506 in this illustrative example.
  • degrees of freedom may refer to the movement of tools 1506 in three-dimensional space.
  • tools 1506 may be arranged on end effector 1508 attached to motion platform 1504.
  • Tools 1506 may include at least one of an inspection system, a clamping system, a sensor system, a fastener system, a drilling system, a positioning system, or other suitable tools.
  • the inspection system may inspect the holes drilled by assembly system 1400.
  • the inspection system also may inspect the fasteners installed by assembly system 1400. Inspection results may be communicated to system controller 214 in some cases.
  • FIG 16 an illustration of a wing in work cell 224 is depicted in accordance with an illustrative embodiment.
  • drivable support system 208 with wing assembly 302 has moved into work cell 224 in the direction of arrow 1404 in Figure 14 .
  • Overhead assembly system 1600 may perform operations on panel 512 in this illustrative example.
  • Overhead assembly system 1600 may be another example of a physical implementation for one of plurality of autonomous tool systems 118 shown in block form in Figure 1 .
  • overhead assembly system 1600 may include motion platform 1602 with tools 1604 on end effector 1606.
  • Motion platform 1602, tools 1604, and end effector 1606 may be implemented in a manner similar to motion platform 1504, tools 1506, and end effector 1508, as described above.
  • Motion platform 1602 may be roughly positioned above panel 512 using overhead support system 1608 equipped with movement system 1610. More precise positioning of motion platform 1602, as well as end effector 1606, is provided by various other moving components associated with overhead assembly system 1600.
  • Overhead assembly system 1600 also may include on-board controller 1612 that communicates with system controller 214 and other components.
  • a dolly (not shown in this view) may be positioned under wing assembly 302 to support wing assembly 302 as supports 402 are separated.
  • Wing assembly 302 may continue with assembly work that does not require precision fixturing until wing assembly 302 is needed for installation in an aircraft.
  • Drivable support system 208 including all or a portion of supports 402, may be moved back to work cell 216 to receive another wing assembly.
  • FIG. 17 an illustration of a top view of work cell 224, shown in the direction of lines 17-17 in Figure 16 is depicted in accordance with an illustrative embodiment.
  • various autonomous tool systems 210 perform operations simultaneously on wing assembly 302.
  • each of autonomous tool systems 210 may perform operations on wing assembly 302 without colliding with one another and/or falling off of wing assembly 302, and so forth.
  • FIG. 18 an illustration of manufacturing environment 200, shown in the direction of lines 18-18 in Figure 16 , is depicted in accordance with an illustrative embodiment. As shown in this view, wing assemblies 204 are being manufactured throughout various work cells 202.
  • Configuration 1800 is a u-shaped configuration in this illustrative example. As depicted, the components within flexible manufacturing system 206 have been rearranged from the configuration shown in Figures 2-17 to form configuration 1800. Because no fixed monument fixtures are used, complete reconfiguration of flexible manufacturing system 206 is possible.
  • an illustrative embodiment completely alleviates the need for, and requirement for, fixed monument fixtures holding a wing assembly, fixed tooling, tools that are fixed to the manufacturing facility, and other inflexible structures.
  • the components within flexible manufacturing system 206 may be reconfigured in some other manner.
  • wing assemblies 204 may be pulsed laterally.
  • autonomous tool systems 210 are free to move about manufacturing environment 200, different autonomous tool systems 210 may be used to manufacture wing assemblies 204 in various work cells 202 at the same time. As a result, multiple wing assemblies 204 may be continuously pulsed through manufacturing environment 200 to increase the efficiency of the manufacturing process. This increase in efficiency leads to a higher production rate than with some currently used systems.
  • Each of the components within manufacturing environment 200 may be reconfigured in this illustrative example. For instance, when a different type of wing is being manufactured, the type of autonomous tool systems 210 used may be different. Further, some of autonomous tool systems 210 may not be needed.
  • supports 402 may hold wing assembly 302 in a vertical configuration.
  • autonomous tool systems 210 may be configured to function differently to perform operations on wing assembly 302.
  • the size of wing assembly 302 may require additional supports 402 to be added to drivable support system 208, additional autonomous tool systems 210 to be used, or a combination thereof.
  • the size of work cells 202 also may be adjusted depending on the length of wing assembly 302. In each case, the components within flexible manufacturing system 206 are reconfigured to meet different manufacturing needs.
  • Figures 19-21 show an alternative implementation for a mobile support system.
  • a bridge system with elongate platforms is shown.
  • connection devices on each drivable support the illustrative examples in Figures 19-21 employ connection devices positioned along the length of an elongate platform.
  • drivable support system 1900 is shown in work cell 1901.
  • Work cell 1901 may be an example of yet another physical implementation for one of plurality of work cells 112 shown in block form in Figure 1 .
  • Work cell 1901 may be part of manufacturing environment 200, shown in Figure 2 , or may be positioned in a different facility.
  • drivable support system 1900 includes drivable supports 1902, elongate platform 1904, and elongate platform 1906.
  • Drivable support system 1900 and drivable supports 1902 are examples of physical implementations for drivable support system 116 and drivable supports 135, respectively, shown in block form in Figure 1 .
  • Elongate platform 1904 and elongate platform 1906 are both examples of physical implementations for elongate platform 177 in Figure 1 .
  • first group 1908 of drivable supports 1902 may be connected to elongate platform 1904.
  • Second group 1910 of drivable supports 1902 may be connected to elongate platform 1906.
  • Elongate platform 1904, elongate platform 1906, or both may have a shape that corresponds to a desired shape of a wing.
  • Each of first group 1908 and second group 1910 of drivable supports 1902 include seven supports evenly spaced underneath a respective elongate platform. Drivable supports 1902 are automated guided vehicles in this example.
  • drivable supports 1902 may be used under each beam, depending on the particular implementation. Spacing between each support also may vary.
  • first group 1908 of drivable supports 1902 may move elongate platform 1904 into a desired position.
  • first group 1908 of drivable supports 1902 may collectively move elongate platform 1904 with respect to a number of axes 1912 to position elongate platform 1904 relative to wing assembly 1914.
  • second group 1910 of drivable supports 1902 may collectively move elongate platform 1906 with respect to axes 1912 to position elongate platform 1904 relative to wing assembly 1914.
  • Wing assembly 1914 is an example of a physical implementation for structure 110 shown in block form in Figure 1 .
  • connection devices 1916 are associated with elongate platform 1904. Connection devices 1916 may be positioned along a length of elongate platform 1904 as shown in this view.
  • connection devices 1918 may be associated with elongate platform 1906. Connection devices 1918 may be positioned along a length of elongate platform 1906 in this illustrative example.
  • Connection devices 1916 and connection devices 1918 may correspond to connection points (obscured in this view) on wing assembly 1914. Connection devices 1916 and connection devices 1918 hold wing assembly 1914 in a desired position. As an example, connection device 1917 connects to point 1919 on wing assembly 1914.
  • Point 1919 may be a connection point that is independently movable using connection device 1917.
  • Point 1919 may be a control point as well as a connection point. In other cases, point 1919 may simply be a fixed connection point that only moves as the elongate platform moves.
  • Connection device 1917 is shown in section 1921 in this illustrative example.
  • human operators 1920 move about elongate platform 1904 and elongate platform 1906.
  • various autonomous tool systems may move about drivable support system 1900 to perform operations on wing assembly 1914.
  • each of drivable supports 1902 may be equipped with a movement system configured to move its corresponding elongate platform with respect to axes 1912. Such movement may include translation, rotation, or some other suitable movement. Drivable supports 1902 dynamically adjust the elongate platforms to keep wing assembly 1914 in alignment, compensate for uneven terrain in the manufacturing environment, allow autonomous tool systems access to wing assembly 1914, balance the load of wing assembly 1914 at any given point, reduce deflection in the beam, or some combination thereof. For example elongate platform 1904 may be moved using a movement system on at least one drivable support in first group 1908 of drivable supports 1902.
  • Elongate platform 1904 and elongate platform 1906 are substantially flat beams in this illustrative example.
  • the upper surface of each beam may be planar with deviations within selected tolerances.
  • Elongate platform 1904 and elongate platform 1906 are manufactured to be substantially flat beams such that misalignments at a point along the beam will reveal misalignments in a corresponding portion of wing assembly 1914 connected to that beam.
  • Adjustments may be made based on position information collected by a metrology system, such as metrology system 120 described in Figure 1 .
  • a metrology system such as metrology system 120 described in Figure 1 .
  • the metrology system may be used to determine flatness of each elongate platform and, from that flatness determination, one or more drivable supports 1902 may be adjusted to bring the entire work plane back into alignment.
  • Elongate platform 1904 and elongate platform 1906 also allow a greater number of connection devices to be used without increasing the number of drivable supports 1902 needed.
  • Connection devices 1916 and connection devices 1918 may be positioned on elongate platform 1904 and elongate platform 1906, respectively, at desired intervals to meet engineering specifications, while still allowing tools to easily maneuver about wing assembly 1914. By using fewer supports, more space is available for tools to perform operations simultaneously.
  • drivable support system 1900 is shown with two elongate platforms and two portions of drivable supports 1902, more than two are possible. For instance, several smaller beams and corresponding drivable supports 1902 may be arranged to form drivable support system 1900.
  • a first set of load sensors may be connected to elongate platform 1904 and configured to identify a load applied to elongate platform 1904 by wing assembly 1914.
  • a second set of load sensors may be connected to elongate platform 1906 and configured to identify a load applied to elongate platform 1906 by wing assembly 1914. These sensors may constantly provide feedback for the system.
  • FIG. 20 an illustration of drivable support system 1900 and wing assembly 1914 shown in the direction of lines 20-20 in Figure 19 is depicted in accordance with an illustrative embodiment.
  • channel 2000 in elongate platform 1904 and channel 2002 in elongate platform 1906 are shown.
  • Channel 2000 and channel 2002 are examples of physical implementations for channel 185 in elongate platform 177 shown in block form in Figure 1 .
  • At least one of channel 2000 and channel 2002 provide a wire raceway in this illustrative example.
  • cables 2004 may run through channel 2000 and cables 2006 may run through channel 2002 to provide utilities to drivable support system 1900, autonomous tool systems working on wing assembly 1914, human operators 1920 using power tools, or a combination thereof.
  • Cables 2004 and cables 2006 are examples of physical implementations for lines 187 from Figure 1 .
  • air lines or other devices may be run through channel 2000, channel 2002, or both.
  • connection device 1917 may have connector 2100.
  • Connector 2100 directly attaches to point 1919 on wing assembly 1914 in this illustrative example.
  • connector 2100 is rigidly connected to wing assembly 1914 at point 1919.
  • one or more of drivable supports 1902 move to bring surface 2102 of elongate platform 1904, and consequently point 1919 of wing assembly 1914, back into alignment.
  • connector 2100 and other components in connection device 1917 may move. However, in the embodiments shown in Figures 19-21 , that type of movement is not required to provide desired alignment for wing assembly 1914.
  • FIG. 2-21 may be illustrative examples of how components shown in block form in Figure 1 can be implemented as physical structures. Additionally, some of the components in Figures 2-21 may be combined with components in Figure 1 , used with components in Figure 1 , or a combination of the two.
  • FIG. 22 an illustration of a flowchart of a process for positioning a tool on a surface is depicted in accordance with an illustrative embodiment.
  • the process described in Figure 22 may be implemented to position autonomous tool system 131 and components within autonomous tool system 131 relative to a surface on structure 110.
  • a combination of components including controller 122, various movement systems, and other devices may be used to position autonomous tool system 131.
  • Metrology system 120 may be used to locate autonomous tool system 131 as it is being positioned.
  • the process may begin by moving autonomous tool system 131 relative to a surface of structure 110 to roughly position autonomous tool system 131 within a selected region on the surface using a first movement system (operation 2200).
  • a first movement system for an autonomous tool system may be movement system 1610 for overhead assembly system 1600 shown in Figure 16 .
  • the process may move autonomous tool system 131 relative to the surface of structure 110 with at least one degree of freedom to precisely position autonomous tool system 131 at a selected position within the selected region on the surface using a second movement system (operation 2202).
  • a second movement system may move motion platform 1602 toward surface 800 of panel 512, as shown in Figure 16 .
  • the process then may align an element associated with autonomous tool system 131 for performing operation 139 at the selected position relative to the selected position using a third movement system (operation 2204), with the process terminating thereafter.
  • the element may be end effector 1508 with tools 1604 as shown in Figure 16 .
  • motion platform 1504 may be the third movement system configured to precisely position end effector 1508 relative to surface 800 of panel 512 at a desired location to perform an operation.
  • FIG 23 an illustration of a flowchart of a process for performing operations 130 on structure 110 is depicted in accordance with an illustrative embodiment.
  • the process illustrated in Figure 23 may be implemented by flexible manufacturing system 102 in manufacturing environment 100 shown in Figure 1 .
  • the process begins by driving drivable support 137 from first location 113 to second location 115 to bring drivable support 137 together with at least one other drivable support to form drivable support system 116 (operation 2300).
  • the process may hold structure 110 in desired position 133 using drivable support system 116 (operation 2302).
  • the process may drive structure 110 from second location 115 to third location 117 on floor 107 of manufacturing environment 100 using drivable support system 116 (operation 2304).
  • the process may then perform operations 130 on structure 110 using plurality of autonomous tool systems 118 (operation 2306), with the process terminating thereafter.
  • operations 130 may be performed on structure 110 while structure 110 is being driven or steered from second location 115 to third location 117.
  • operations 130 may be performed while structure 110 is being carried by drivable support system 116.
  • Plurality of autonomous tool systems 118 may be driven to third location 117 from various locations 103 in manufacturing environment 100 to perform these operations.
  • FIG. 24 an illustration of a flowchart of a process for operating flexible manufacturing system 102 to perform operations on structure 110 is depicted in accordance with an illustrative embodiment.
  • the process may begin by generating metrology data 154 for a component within flexible manufacturing system 102 (operation 2400).
  • metrology system 120 may be used to identify a current position for at least one of drivable support system 116, plurality of autonomous tool systems 118, or structure 110.
  • controller 122 may command autonomous tool system 131 to drive between locations 103 in manufacturing environment 100. Controller 122 may steer autonomous tool system 131 to avoid collisions with other components in manufacturing environment 100.
  • Operation 2406 may be implemented using metrology system 120 to provide feedback control 199.
  • controller 122 may assign and reassign tasks to the component, take the component offline, reposition the component, command the component to perform an action, or a combination thereof.
  • controller 122 may control operation of plurality of autonomous tool systems 118 throughout operations 130.
  • metrology system 120 may continuously generate metrology data 154 to ensure that components within flexible manufacturing system 102 are in a desired position.
  • FIG 25 an illustration of a flowchart of a process for controlling operation of plurality of autonomous tool systems 118 is depicted in accordance with an illustrative embodiment.
  • the process illustrated in Figure 25 may be implemented by controller 122 as part of operation 2408 in Figure 24 .
  • the process begins by determining whether operations 130 need to be performed on structure 110 (operation 2500). If operations need to be performed, the process then identifies tasks 111 to be performed on structure 110 (operation 2502). Controller 122 may prioritize tasks 111 in some cases.
  • the process assigns tasks 111 to plurality of autonomous tool systems 118 (operation 2504).
  • the process then sends commands 166, with the assigned tasks 111, to plurality of autonomous tool systems 118 (operation 2506).
  • the process monitors status 170 of tasks 111 assigned to plurality of autonomous tool systems 118 (operation 2508).
  • the process also monitors status 172 of plurality of autonomous tool systems 118 (operation 2510). The process then reassigns tasks 111 between plurality of autonomous tool systems 118 based on at least one of status 170 of tasks 111 or status 172 of plurality of autonomous tool systems 118 (operation 2512), returning to operation 2500 thereafter.
  • wing 108 may be complete.
  • the process described in Figure 25 may temporarily terminate and be reinitiated at a later time.
  • Figure 26 an illustration of a flowchart of a process for management of a manufacturing environment is depicted in accordance with an illustrative embodiment. The process illustrated in Figure 26 may be used to reconfigure manufacturing environment 100 shown in block form in Figure 1 based on manufacturing needs.
  • the process begins by determining manufacturing parameters 132 for product 104 (operation 2600).
  • the process reconfigures flexible manufacturing system 102 based on manufacturing parameters 132 (operation 2602).
  • at least one of drivable support system 116, plurality of autonomous tool systems 118, or metrology system 120 may be reconfigured based on manufacturing parameters 132 for wing 108.
  • the process then performs operations 130 on structure 110 based on manufacturing parameters 132 for product 104 (operation 2604). As operations 130 are being performed, the process monitors the health of flexible manufacturing system 102 (operation 2606).
  • the health of flexible manufacturing system 102 may include status 172 of plurality of autonomous tool systems 118, status 129 of operations 130, and the position of human operator 142, among others.
  • flexible manufacturing system 102 is reconfigurable based on manufacturing parameters 132 for wing 108.
  • Flexible manufacturing system 102 is also reconfigurable in real-time based on changes monitored by controller 122.
  • FIG. 27 an illustration of a flowchart of a process for using a drivable support system to build a wing assembly is depicted in accordance with an illustrative embodiment.
  • the process illustrated in Figure 27 may be implemented using drivable support system 116 with elongate platform 177 shown in block form in Figure 1 .
  • the process may begin by driving a first group of drivable supports 135 connected to a first elongate platform from first location 113 to second location 115 to bring the first group of drivable supports together with second group of drivable supports 135 connected to a second elongate platform (operation 2700).
  • the first group of drivable supports 135 with the first elongate platform may be a front spar tooling system in this illustrative example.
  • the process may then drive a second group of drivable supports 135 connected to a second elongate platform to position the second elongate platform relative to the first elongate platform (operation 2702).
  • the second group of drivable supports 135 with the second elongate platform may be a rear spar tooling system.
  • end supports may be installed between the first elongate platform and the second elongate platform (operation 2704). End supports may be optional components used to enhance the stability of the system.
  • the process may identify a position for the first elongate platform and the second elongate platform (operation 2706).
  • metrology data 154 may be generated for each elongate platform using metrology system 120.
  • the process may then determine whether the position of the first elongate platform and the second elongate platform correspond to a desired position for the first elongate platform and the second elongate platform (operation 2708). If the position and the desired position correspond within selected tolerances, the process may continue to operation 2722.
  • the desired position for the elongate platforms is a position that will ensure alignment, within selected tolerances, of parts of the wing assembly.
  • the process may adjust the position of at least one of the first elongate platform and the second elongate platform (operation 2710).
  • the position of the elongate platforms is adjusted by moving drivable supports 135 as needed to flatten the work plane.
  • a first group of structural members may be positioned relative to the first elongate platform and the second elongate platform (operation 2712).
  • front and rear spars may be loaded onto each respective elongate platform by attaching the spars to various connection devices along the length of the elongate platforms.
  • a second group of structural members may be positioned relative to the first group of structural members and aligned using index features (operation 2714).
  • ribs may be loaded between spars and indexed accordingly to form a ladder assembly.
  • the process may then determine whether the position of the first elongate platform and the second elongate platform have changed (operation 2716). For instance, metrology system 120 may scan drivable support system 116 again to make sure the first elongate platform and the second elongate platform are substantially flat.
  • the process proceeds to operation 2722. If the position has changed, the process again may adjust the position of at least one of the first elongate platform and the second elongate platform (operation 2718).
  • drivable supports 135 may be fixed in place such that drivable supports 135 do not move in an undesired manner.
  • the wheels attached to drivable supports 135 may be locked or retracted.
  • the process then may perform operations 130 to build wing assembly 105 (operation 2722), with the process terminating thereafter.
  • upper skin panel 184 may be loaded and tacked to the structural member.
  • Plurality of autonomous tool systems 118 may move about drivable support system 116 to perform operations 130.
  • metrology system 120 may be used to confirm proper alignment of the first elongate platform and the second elongate platform.
  • other sensors such as load sensors, may provide force sensor feedback to not overload wing assembly 105, drivable support system 116, or both.
  • drivable support system 116 may move wing assembly 105 to other locations within manufacturing environment 100.
  • Force sensors, as well as metrology system 120, may be employed to ensure load balancing, as well as precise positioning of the first elongate platform and the second elongate platform.
  • each group of drivable supports 135 and its respective elongate platform may need to be attached to one another.
  • a position of drivable supports 135 relative to structure 110 in manufacturing environment 100 may be determined using metrology system 120.
  • a number of the drivable supports 135 may be driven to first location 113 to form the first group of drivable supports 135 based on a proximity of the number of drivable supports 135 to structure 110. For example, the four drivable supports 135 that are closest to structure 110 and available for use may be driven to first location 113 to form first group of drivable supports 135. The first group of drivable supports 135 may then be connected to the first elongate platform.
  • the second group of drivable supports 135 may be formed in a similar fashion and subsequently attached to the second elongate platform. In this manner, drive control system 121 may efficiently allocate drivable support resources within manufacturing environment 100, further expediting the build process for structure 110.
  • each block in the flowcharts or block diagrams may represent at least one of module, a segment, a function, or a portion a combination thereof of an operation or step.
  • the function or functions noted in the blocks may occur out of the order noted in the figures.
  • two blocks shown in succession may be executed substantially concurrently, or the blocks may sometimes be performed in the reverse order, depending upon the functionality involved.
  • other blocks may be added in addition to the illustrated blocks in a flowchart or block diagram.
  • Data processing system 2800 may be used to implement one or more computers in computer system 164 in Figure 1 .
  • data processing system 2800 includes communications framework 2802, which provides communications between processor unit 2804, storage devices 2806, communications unit 2808, input/output unit 2810, and display 2812.
  • communications framework 2802 may be implemented as a bus system.
  • Processor unit 2804 is configured to execute instructions for software to perform a number of operations.
  • Processor unit 2804 may comprise a number of processors, a multi-processor core, some other type of processor, or some combination thereof, depending on the implementation.
  • processor unit 2804 may take the form of a hardware unit, such as a circuit system, an application specific integrated circuit (ASIC), a programmable logic device, or some other suitable type of hardware unit.
  • ASIC application specific integrated circuit
  • Storage devices 2806 may be in communication with processor unit 2804 through communications framework 2802.
  • a storage device also referred to as a computer readable storage device, is any piece of hardware capable of storing information on a temporary basis, permanent basis, or both. This information may include, but is not limited to, at least one of data, program code, or other information.
  • Memory 2814 and persistent storage 2816 are examples of storage devices 2806.
  • Memory 2814 may take the form of, for example, a random access memory or some type of volatile or non-volatile storage device.
  • Persistent storage 2816 may comprise any number of components or devices.
  • persistent storage 2816 may comprise a hard drive, a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of the above.
  • the media used by persistent storage 2816 may or may not be removable.
  • Communications unit 2808 allows data processing system 2800 to communicate with other data processing systems, devices, or some combination thereof. Communications unit 2808 may provide communications using physical communications links, wireless communications links, or a combination thereof.
  • Input/output unit 2810 allows input to be received from and output to be sent to other devices connected to data processing system 2800.
  • input/output unit 2810 may allow user input to be received through at least one of a keyboard, a mouse, or some other type of input device.
  • input/output unit 2810 may allow output to be sent to a printer connected to data processing system 2800.
  • Display 2812 is configured to display information to a user.
  • Display 2812 may comprise, for example, without limitation, selected from one of a monitor, a touch screen, a laser display, a holographic display, a virtual display device, or some other type of display device.
  • processor unit 2804 may perform the processes of the different illustrative embodiments using computer-implemented instructions. These instructions may be referred to as program code, computer usable program code, or computer readable program code and may be read and executed by one or more processors in processor unit 2804.
  • program code 2818 is located in a functional form on computer readable media 2820, which is selectively removable, and may be loaded onto or transferred to data processing system 2800 for execution by processor unit 2804.
  • Program code 2818 and computer readable media 2820 together form computer program product 2822.
  • computer readable media 2820 may be computer readable storage media 2824 or computer readable signal media 2826.
  • Computer readable storage media 2824 is a physical or tangible storage device used to store program code 2818 rather than a medium that propagates or transmits program code 2818.
  • Computer readable storage media 2824 may be, for example, without limitation, an optical or magnetic disk or a persistent storage device that is connected to data processing system 2800.
  • program code 2818 may be transferred to data processing system 2800 using computer readable signal media 2826.
  • Computer readable signal media 2826 may be, for example, a propagated data signal containing program code 2818. This data signal may be an electromagnetic signal, an optical signal, or some other type of signal that can be transmitted over physical, wireless communications links, or some combination thereof.
  • data processing system 2800 in Figure 28 is not meant to provide architectural limitations to the manner in which the illustrative embodiments may be implemented.
  • the different illustrative embodiments may be implemented in a data processing system that includes components in addition to or in place of those illustrated for data processing system 2800. Further, components shown in Figure 28 may be varied from the illustrative examples shown.
  • aircraft manufacturing and service method 2900 may be described in the context of aircraft manufacturing and service method 2900 as shown in Figure 29 and aircraft 3000 as shown in Figure 30 .
  • Figure 29 an illustration of an aircraft manufacturing and service method is depicted in the form of a block diagram in accordance with an illustrative embodiment.
  • aircraft manufacturing and service method 2900 may include specification and design 2902 of aircraft 3000 in Figure 30 and material procurement 2904.
  • aircraft 3000 in Figure 30 During production, component and subassembly manufacturing 2906 and system integration 2908 of aircraft 3000 in Figure 30 takes place. Thereafter, aircraft 3000 in Figure 30 may go through certification and delivery 2910 in order to be placed in service 2912. While in service 2912 by a customer, aircraft 3000 in Figure 30 is scheduled for routine maintenance and service 2914, which may include modification, reconfiguration, refurbishment, and other maintenance or service.
  • Each of the processes of aircraft manufacturing and service method 2900 may be performed or carried out by a system integrator, a third party, an operator, or a combination thereof.
  • the operator may be a customer.
  • a system integrator may include, without limitation, any number of aircraft manufacturers and major-system subcontractors
  • a third party may include, without limitation, any number of vendors, subcontractors, and suppliers
  • an operator may be an airline, a leasing company, a military entity, a service organization, and so on.
  • aircraft 3000 is produced by aircraft manufacturing and service method 2900 in Figure 29 and may include airframe 3002 with plurality of systems 3004 and interior 3006.
  • systems 3004 include one or more of propulsion system 3008, electrical system 3010, hydraulic system 3012, and environmental system 3014. Any number of other systems may be included.
  • propulsion system 3008 include one or more of propulsion system 3008, electrical system 3010, hydraulic system 3012, and environmental system 3014. Any number of other systems may be included.
  • an aerospace example is shown, different illustrative embodiments may be applied to other industries, such as the automotive industry.
  • Apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method 2900 in Figure 29 .
  • flexible manufacturing system 102 from Figure 1 may be used during various stages of aircraft manufacturing and service method 2900 to perform operations 130 on airframe 3002.
  • flexible manufacturing system 102 may be used to perform operations 130 during component and subassembly manufacturing 2906.
  • Components within flexible manufacturing system 102 also may be reconfigured for use during system integration 2908, routine maintenance and service 2914, or some other stage of aircraft manufacturing and service method 2900.
  • plurality of autonomous tool systems 118 also may be used to rework portions of airframe 3002 during routine maintenance and service 2914.
  • components or subassemblies produced in component and subassembly manufacturing 2906 in Figure 29 may be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft 3000 is in service 2912 in Figure 29 .
  • one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during production stages, such as component and subassembly manufacturing 2906 and system integration 2908 in Figure 29 .
  • One or more apparatus embodiments, method embodiments, or a combination thereof may be utilized while aircraft 3000 is in service 2912, during maintenance and service 2914 in Figure 29 , or a combination thereof.
  • the use of a number of the different illustrative embodiments may substantially expedite the assembly, reduce the cost of aircraft 3000, or both.
  • the illustrative embodiments may provide a method and apparatus for performing operations 130 on product 104 for aircraft 109.
  • Product 104 may take the form of wing 108 for aircraft 109.
  • Flexible manufacturing system 102 may comprise drivable support system 116, plurality of autonomous tool systems 118, metrology system 120, and controller 122.
  • Drivable support system 116 may be configured to hold structure 110 in desired position 133 and move with structure 110 between plurality of work cells 112 during performance of operations 130.
  • Plurality of autonomous tool systems 118 may be configured to perform operations 130 on structure 110 and move with drivable support system 116.
  • Metrology system 120 may be configured to generate metrology data 154 for at least one of drivable support system 116, plurality of autonomous tool systems 118, or structure 110 and move with drivable support system 116.
  • Controller 122 may be in communication with metrology system 120 and plurality of autonomous tool systems 118. Controller 122 may be configured to control operation of plurality of autonomous tool systems 118 using metrology data 154. At least one of drivable support system 116, plurality of autonomous tool systems 118, or metrology system 120 may be reconfigurable.
  • wing 108 may be assembled without the use of fixed monument fixtures at different locations within manufacturing environment 100.
  • Flexible manufacturing system 102 is completely reconfigurable to take into consideration changing manufacturing conditions. Components within flexible manufacturing system 102 can be reconfigured to modify the length of the assembly line, perform more operations at a single location, or a combination thereof.
  • the illustrative embodiments also increase the speed at which wing 108 is assembled.
  • Plurality of autonomous tool systems 118 automate various operations using robotic devices.
  • Plurality of autonomous tool systems 118 are also configured such that structure 110 does not have to be lifted as high as with some currently used systems.
  • assembly system 1400 as shown in Figure 14 , are designed such that the wing assembly can be set lower.
  • flexible manufacturing system 102 includes various safety features and controls features integrated within the system.
  • bridge system 136 and rail system 138 provide the necessary access for human operators, while also providing fall protection 144.
  • Controller 122 controls each of the components in flexible manufacturing system 102 such that undesired encounters between components, between components and the ground, and between components and human operators, may be reduced or eliminated.
  • An illustrative embodiment may reconfigure components to support structure 110 in various ways.
  • bridge system 136 When bridge system 136 is equipped with elongate platforms, a number of additional connection devices 195 may be used to hold and align parts of structure 110 relative to one another.
  • the implementation of elongate platforms in drivable support system 116 provides additional connections to structure 110 without adding the cost of an additional drivable support.
  • using fewer drivable supports 135 results in more room to maneuver plurality of autonomous tool systems 118 between drivable supports 135 and promotes greater access to structure 110. Fewer sensors also may be used to accurately track and align the elongate platforms.
  • drivable support system 116 is freely movable about manufacturing environment 100, no monuments or other fixed structures are needed. With the use of an illustrative embodiment, operators do not have to remove structure 110 from fixed monument fixtures and reposition it in different work cells. Rather, drivable support system 116 moves as structure 110 moves. In this manner, manufacturing time needed for wing 108 is reduced. Further, the number of human operators performing operations also may be reduced. As a result, cost savings may be realized.

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US20200030925A1 (en) 2020-01-30
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